Charge Air Cooler Hose, Disconnecting And Connecting

WARNING: This page is about a different car, the 2014 Volkswagen Jetta, 2013 Volkswagen Jetta, 2012 Volkswagen Jetta, and 2011 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:

NOTE:

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

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

Fig 1: Identifying Pushing Charge Air Cooler Hose Coupling

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Bring the clip -1- into the released position -arrow 2- as shown.

-- 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 into the released position -1-.

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 into the locking position -4-. 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-.

Fig 4: Identifying Clip In Release And Lock Positions

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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.

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