Charge air cooler (intercooler), removing and installing

This description applies to the right charge air cooler. The procedure is the same for the left charge air cooler, except that the activated charcoal filter does not have to be removed.

Fig 1: Removing Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove sound insulation (arrows).
Remove front bumper.

Refer to 63 BUMPERS ; Front bumper; Removing and installing

Remove right headlight

Refer to 94 LIGHTS, SWITCHES - EXTERIOR ; Servicing headlights; Removing and installing headlights

Remove activated charcoal filter.

Refer to

20 - FUEL PUMP, FUEL SUPPLY, EVAPORATIVE EMISSIONS for 1.8 LITER 4-CYL. 5V TURBO GENERIC SCAN TOOL ENGINE CODE(S): AMU, BEA, ATC, AWP
20 - FUEL SUPPLY for 3.2 LITER V6 4V GENERIC SCAN TOOL, ENGINE CODE: BHE

; Servicing parts of activated charcoal filter system (front-wheel drive and all-wheel drive)

Fig 2: Identifying Connecting Line Bolts (Left)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove connecting line between charge air coolers from longitudinal members on left side...

Fig 3: Identifying Connecting Line Bolts & Right Charge Air Coolers

Courtesy of VOLKSWAGEN UNITED STATES, INC.

... and right side: Disconnect hoses from both charge air coolers.
Remove connecting line.
Disconnect air hose from top of charge air cooler.

Fig 4: Removing Bolts For Charge Air Cooler

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove 2 bolts (arrows) for charge air cooler.
Unclip air duct from charge air cooler.
Remove lower securing bolt -1- for charge air cooler.
Take out charge air cooler from underneath.

Installation is carried out in the reverse order, when doing this note the following:

Adjust headlights.

Refer to 01 MAINTENANCE ; Description of work; Headlights - checking settings and adjusting if necessary