Charge Air Cooler

WARNING: This page is about a different car, the 2013 Volkswagen Jetta and 2012 Volkswagen Jetta. 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 Ties

Removing

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

-- Remove the bumper cover. Refer to "Front Bumper" in Removing .

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

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

Fig 1: Air Guide Hose

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove fan shroud. Refer to FAN SHROUD .

-- Remove the radiator. Refer to RADIATOR .

-- Remove the bolts -2- from the charge air cooler mounts.

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

-- Lift the charge air cooler out of the lower mounting.

-- 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 .