Charge air cooling system components, removing and installing

Fig 1: Charge Air Cooling System Components, Removing And Installing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Part 1

NOTE:

All hose connections must be secured with hose clips (same as original parts).
Before carrying out tests or repair work, make sure that all pipes and hoses are securely connected and that there are no leaks.

1 - Pressure hose

2 - To connection on charge air cooler

3 - 20 Nm

4 - Bottom bracket for pressure line

5 - Pressure pipe

6 - Top bracket for pressure line

7 - 20 Nm

8 - 20 Nm

9 - Top bracket for pressure line

10 - Pressure hose

11 - Turbocharger

12 - To crankcase breather

13 - Pressure regulating valve for crankcase breather

14 - Pressure unit for charge air pressure control

15 - Air intake hose

16 - To air cleaner

17 - To Recirculating valve for turbocharger -N249-

18 - Charge air pressure bypass valve

19 - Connecting piece

20 - Recirculating valve for turbocharger -N249-

21 - Bottom bracket for pressure line

Part 2

1 - Pressure hose

2 - Air duct for charge air cooler (right)

3 - Charge air cooler (right)

Removing and installing. Refer to Charge air cooler (intercooler), removing and installing

4 - Rubber grommet

With sleeve

5 - 10 Nm

6 - To turbocharger

7 - 10 Nm

8 - Bracket for charge air cooler (right)

9 - Connection on intake manifold

10 - Rubber grommet

With sleeve

11 - 10 Nm

12 - Bracket

Secured on longitudinal member

13 - Sleeve

14 - Rubber grommet

15 - Pressure hose

With clip for wire to charge air pressure sensor -G31-

16 - 10 Nm

17 - 10 Nm

18 - Charge air pressure sensor -G31-

19 - Pressure line

20 - Pressure hose

21 - 10 Nm

22 - Rubber grommet

23 - Charge air cooler (left)

24 - 10 Nm

25 - Rubber grommet

26 - Bracket for charge air cooler

27 - Air duct for charge air cooler (left)

28 - Connecting line between left and right charge air coolers