Charge air cooler components, assembly overview

WARNING: This page does not describe the selected car, but rather 15 other vehicles, including the 2006 Volkswagen GTI, 2005 Volkswagen Jetta, 2005 Volkswagen GTI, 2004 Volkswagen Jetta, and 2004 Volkswagen GTI. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Various hose connections are secured with clamps.
Charge air system must be properly sealed.
When installing, follow installation marks on hoses and components.
Note installation position of heat shield mats

Fig 1: Charge Air Cooler Components, Assembly Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Air duct

2 - 10 Nm

3 - Charge Air Pressure Sensor G31

Checking refer to Charge Air Pressure Sensor G31 , checking

4 - O-ring

Replace

5 - Rubber grommet

With sleeve

6 - 10 Nm

7 - Intake tube

Between intake manifold and charge air cooler

8 - Heat shield mats

Note installation position

9 - Screw clamp

Only vehicles with engine code AWD
Vehicles with engine code AWP, AWW with quick-release connection (with O-ring and retaining clip)

10 - Connecting hose

11 - Air guide pipe

12 - Bracket

13 - Connecting hose

14 - Air charge cooler