PLM Heat Exchanger install for B8S4 / S5.

Tools and Supplies needed:

Oetiker Pliers for Factory hose clamps
Radiator pinch clamp
Channel lock pliers
Bucket to catch drained coolant
Aprox 1.5 gallons of Coolant/Distilled water
5mm Allen wrench
Drill
Ratchet
3/8 socket
16mm socket
17mm socket
13mm socket
10mm socket (used for bumper fender bolts)
T25 Torx (used for fender liner , underbelly try and bumper)
T30 torx
1) Ensure that all the hardware is complete:
The Heat Exchanger comes with:

The Coolant Tank comes with:

2) Remove the front bumper and the underbelly tray.

3) Remove the Shroud from the driver side by pulling outwards.

4) Using the radiator clamp pliers, pinch off the coolant hose that routes to the heat exchanger.

5) Place a bucket under the lower heat exchanger hose connection.

6) Remove the lower factory heat exchanger hose with a pair of channel lock pliers. (Note on the
B8.5 the connections are both on the driver side of the car)

7) Drain the coolant in the bucket.

8) Remove the hose from the driver side of the heat exchanger with some channel locks.

9) Remove the T30 screw holding the Heat Exchanger.

10) The passenger side of the Heat Exchanger has a plastic clip/lock that you press down to release.

11) Remove the Factory Heat Exchanger.

12) Disconnect the ambient temperature sensor and clip from the support bar.

13) Disconnect the horn and harness clip on the passenger side.

14) Disconnect the horn and harness clip on the driverside.

15) Remove the (4) 13mm bolts that hold the support on. There are (2) on each side.

16) With the support off, and the rear side up, mark the center (22 inches).

17) From the centerline, mark out 2 lines from each side 13 inches.

18) Temporary mount the brackets to the Heat Exchanger with the 5mm allen screws and center it
within the 2 outer marks that were made(red mark).

19) Draw marks along the edge of the bracket for the final placement (blue mark).
20) Remove the brackets from the heat exchanger.
21) Place the bracket on the support and mark the (4) holes. Align the top of the bracket with the
top of the support. Repeat on the other side (4) holes.

22) Drill out the (8) holes that were marked.

23) Install the brackets back onto the support using a 3/8 socket.

24) Install the Heat Exchanger to the brackets with a 5mm Allen wrench with the screw and lock
washer.

25) Install the support with the Heat Exchanger back onto the car with the bolts removed earlier.
Plug back in the ambient temp sensor and horns.
26) Using the hose with the J bend and the barb fitting that came with the Heat Exchanger, connect
it to the driver side of the stock hose using the stock clamp.

27) Connect the other end of the J hose to the Heat Exchanger.

28) Remove the (2) 16mm bolts from the bottom of the support bracket on the passenger side.

29) Replace the (2) bolts with the 17mm longer bolts included with the kit. Place a Flat washer on
the bolts before installing them.

30) Install the bracket onto the coolant tank with a 5mm allen wrench using the provided screws
and lock washers.

31) Attach the J hose that came with the coolant tank using the reducing barb (5/8 to ) to the
smaller diameter hose(3/4) that was included with the Heat exchanger. (Note if installing this in
a B8.5, use the longer smaller diameter hose(3/4) that was included with the Coolant Tank)

32) Remove the rubber caps from the coolant tank and install the J hose to the top of the tank as
pictured.

33) Install the (2) machined spacers onto the 17mm bolts that were installed earlier. You may have
to remove a clip that is attached to the frame that is holding a harness.

34) Install the Coolant tank onto the 17mm bolts on the car. Secure with the lock washer and nut.
Using a gear wrench to tighten is easiest since it is a very tight spot.

35) Attach the hose that ran from the top of the Coolant Tank to the lower pipe of the car using the
original clamp. You may need to cut the hose shorter if it is too long and kinking. (For the B8.5,
run the longer hose along the front radiator support and attach the U shaped hose to the long
hose using the supplied barb fitting)

36) Attach the 5/8 hose to the front of the Coolant tank and connect to the lower part of the Heat
Exchanger.

37) Remove the clamp pliers from the coolant line. Refill the coolant and bleed the system.
Preferred method is using an air bleeder. Check for any leaks. The system will use about 1.5
gallons. (If no air bleeder is available, there are (2) bleeder screws on top of the supercharger)

38) Re install the shroud on the driver side and then the bumper. Dont forget to plug in the fog
lights and homelink.
39) Drive around and re-check the coolant level and for any leaks.