Charge Air Cooler

WARNING: This page is about a different car, the 2010 Volkswagen Jetta, 2009 Volkswagen Jetta, 2009 Volkswagen GLI, 2008 Volkswagen Jetta, and 2008 Volkswagen GLI. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Torque Wrench V.A.G 1783
Cable Tie

Removing

-- Remove the noise insulation. Refer to Description and Operation .

-- Remove the bumper cover. Refer to "Front Bumper" in Removal and Installation .

-- Drain the coolant. Refer to DRAINING AND FILLING .

-- Loosen the clamps -arrows- and remove the right charge air hose.

Fig 1: Identifying Right Charge Air Guide Hose

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-- Remove the fan shroud. Refer to FAN SHROUD .

-- Remove the radiator. Refer to RADIATOR .

The Air Conditioning (A/C) condenser pipes are bolted to the right side of the charge air cooler. To remove the bolt, proceed as follows:

-- Create a paper template with the specified dimensions.

Fig 2: Identifying Paper Template Specified Dimensions

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-- Position the template on the right front plastic support so it aligns with the top and left edges.

Fig 3: Identifying Position Of Template On Right Front Plastic Support

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-- Mark the cutting point on the template -arrow- with a punch.

-- Drill a hole in the plastic support with a 5 mm drill bit.

-- Drill or cut the hold to 16 mm.

-- Remove the bolt -arrow- for the A/C condenser pipes.

Fig 4: Identifying Bolt For Condenser Pipes

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-- Remove the charge air cooler bracket bolts -1-.

Fig 5: Identifying Charge Air Cooler Mount Bolts

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-- Push the charge air cooler toward the rear and remove the mounts that are on the side.

CAUTION:

To prevent damage to the A/C condenser and the refrigerant lines, do not stretch, kink or bend the pipes and hoses.

NOTE:

The A/C condenser bolts are difficult to access. With the help of a second technician, lift the charge air cooler out of the lower mounts. Now the charge air cooler can be tilted >>back and forth<< and the bolts are accessible.

-- Remove the A/C condenser bolts -arrows- from the charge air cooler.

Fig 6: Identifying Condenser Bolts

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-- Secure the A/C condenser to the lock carrier with cable ties.

-- Remove the charge air cooler downward.

Installing

CAUTION:

The charge air pipe clamps must be tightened to 5.5 Nm. An insufficient or excessive tightening torque can cause the charge air hose to come off the charge air pipe while driving.

For tightening specifications, refer to CHARGE AIR COOLER COMPONENT OVERVIEW .

Install in reverse order of removal. When doing this note the following:

Hose connections and charge air system hoses must be free of oil and grease before installing. Sealing ring and sealing surfaces must only be lightly oiled with connector couplings. Refer to CHARGE AIR HOSE AND PIPE, DISCONNECTING AND CONNECTING .
Install only approved clamps for securing hose connections.
Charge air hose connecting and disconnecting. Refer to CHARGE AIR HOSE AND PIPE, DISCONNECTING AND CONNECTING .