Left and right charge air coolers, removing and installing

WARNING: This page is about a different car, the 2009 Audi A4, 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

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

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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.

Remove refrigerant line - 4 - from bracket.
Remove hose clamps - 1 - and - 2 - and disconnect air guide hoses.
Remove charge air cooler upward and out.

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