Left and right charge air coolers, removing and installing

NOTE:

The following removal and installation procedure is for the left charge air cooler. The procedure for the right charge air cooler is identical.
Before a test or repair, verify that all hoses and lines are securely installed and not leaking.

Removing

Fig 1: Identifying Exhaust Pipe Fasteners

Courtesy of VOLKSWAGEN UNITED STATES, INC.

For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

Fig 2: Identifying Quick-Release Fasteners And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
Remove quick-release fasteners - 3 - and remove rear noise insulation, if installed.
Remove front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
Remove left and right headlights → 94 LIGHTS, SWITCHES - EXTERIOR .

Fig 3: Removing Air Guides From In Front Of Charge Air Coolers At Left/Right

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove air duct from in front of charge air cooler at left and right - arrows -.

Fig 4: Disconnecting Electrical Harness Connector To Charge Air Pressure Sensor G31

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - 3 - to Charge Air Pressure Sensor G31.

CAUTION: The air conditioning refrigerant circuit must not be opened.

Installing

Installation is in reverse order of removal, note the following:

NOTE:

Hose connections and charge air system hoses must be free of oil and grease before installing.
Secure all hose connections using hose clamps appropriate for the model type .

Install headlights → 94 LIGHTS, SWITCHES - EXTERIOR .
Install front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
Check headlight adjustment →
- 01 - MAINTENANCE
- 01 - MAINTENANCE for MAINTENANCE PROCEDURES - CABRIOLET
.

Torque specifications

Component	Nm
Hose clamps 13 mm wide	5.5