Charge Air Cooler Hose, Disconnecting And Connecting

WARNING: This page is about a different car, the 2010 Volkswagen Jetta and 2009 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

Follow the safety precautions when working on the charge air system and turbocharger. Refer to SAFETY PRECAUTIONS .
Observe rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Always follow these instructions before and during work.

Disconnecting

With a Positioning Tab:

-- Push the charge air cooler hose coupling -arrow 1- together.

Fig 1: Push The Charge Air Cooler Hose Coupling

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The clip -1- can only be released completely by pushing the coupling together.

-- Bring the clip -arrow 2- into the released position.

-- Disconnect the coupling without using tools.

Without a Positioning Tab:

-- Release the coupling by pulling the clip -1-. Remove the hose -2- without using a tool.

Fig 2: Disengaging Connector Coupling And Disconnecting Pressure Hose From Coupling

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Connecting

With a Positioning Tab

CAUTION:

The coupling sealing ring can be damaged if the clamp is in the locked position when installing. This would result in a leak. Follow assembly instructions.

-- Clean the sealing surfaces in the coupling.

-- When replacing the sealing ring, place it in the groove on the hose. Ensure the sealing ring is completely seated in the groove all the way around.

-- Lightly oil the sealing surfaces and the sealing ring.

-- Bring the clip -1- into the released position.

Fig 3: Slide The Hose Onto The Charge Air Cooler

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Slide the hose onto the charge air cooler as far as the stop. Check the positioning tab -2-.

-- Bring the clip -4- into the locking position. The clip then engages in the securing groove -3-.

-- Pull the hose back again.

-- Pull on the hose to make sure it is seated correctly and the coupling is engaged.

Without a Positioning Tab

-- When replacing the sealing ring, lay the ring in the charge air hose groove. Ensure the sealing ring is completely seated in the groove all the way around.

-- Oil the sealing surfaces and sealing ring.

-- Bring the securing clip into the released position -1-.

-- Slide the hose onto the charge air cooler as far as the stop.

-- Bring the securing clip into the locked position -2- and then push the hose back again.

Fig 4: Identifying Clip In Release And Lock Positions

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Check for correct seating and proper locking of the connector by pulling on the hose.