Charge air cooler components, assembly overview

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

NOTE:

Charge air system must be properly sealed.
Various hose connections are secured with clamps. For connector couplings, always note the following points:

Fig 1: Identifying Hose/Tube Retaining Tabs

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Release connection by pulling retaining clip - arrow -.
Disconnect hose/pipe without tools.
When assembling, make sure retaining tabs - A - are engaged securely.

Fig 2: Exploded View Of Charge Air Cooler Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Air charge cooler

2 - 10 Nm

3 - Bracket

4 - Connecting hose

5 - Connecting pipe

Charge air cooler/intake manifold

6 - O-ring

Replace if damaged

7 - Intake Air Temperature (IAT) Sensor G72

12.98 → on charge air cooler

8 - 5 Nm

9 - Connecting hose

Connection pipe/intake manifold

10 - Connecting hose

Charge air pipe/turbocharger

11 - Charge air pipe

With muffler