Charge Air Cooler: Removing

-- Open the clamps -1- and -2- and remove the charge air line.

Fig 1: Identifying Clamps

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Open the clamps -1- and -2- and remove the charge air line.

Fig 2: Identifying Hose Clamps

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Seal the open lines and connections with clean plugs from the Engine Bung Set VAS 6122.

-- Remove the radiator. Refer to RADIATOR .

-- Remove the bumper cover. Refer to Removal and Installation .

Vehicles with A/C

The 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 3: Identifying Paper Template And Specified Dimensions

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 4: Identifying Position Of Template On Right Front Plastic Support

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

-- Drill or cut a 16 mm hole.

-- Remove the bolt -arrow- for the condenser pipe.

Fig 5: Identifying Bolt For Condenser Pipes

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

For all vehicles

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

Fig 6: Identifying Charge Air Cooler Mount Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Vehicles with A/C

-- Remove the condenser from the charge air cooler -arrows-.

Fig 7: Identifying Condenser Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Attach the condenser and the cable tie to the lock carrier.

For all vehicles

-- Remove the charge air cooler downward.