Overview - Charge Air System

Fig 1: Charge Air System Exploded View

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Coolant Hose
2. Bolt
   • 15 Nm
   • Thread cutting
   • Position the bolt by hand and tighten it until it finds the old threads, then tighten the bolt to the tightening specification
3. Coolant Hose
4. Coolant Hose
5. Charge Air Cooler
   • Removing and installing. Refer to CHARGE AIR COOLER, REMOVING AND INSTALLING .
   • Fill with coolant after the assembly. Refer to Filling .
6. Sealing Lip
   • Replace after removing.
   • Coat before installing with clean engine oil.
7. Seal
   • Replace after removing.
8. Intake Manifold
   • Removing and installing. Refer to INTAKE MANIFOLD, REMOVING AND INSTALLING .
9. Bolt
   • Tightening specification and sequence. Refer to OVERVIEW - INTAKE MANIFOLD .
10. O-Ring
    • Replace after removing.
11. Intake Manifold Sensor -GX9-
    • Consists of:

      Intake Air Temperature Sensor 2 -G299-

      Manifold Absolute Pressure Sensor -G71-

    • Removing and installing. Refer to Intake Manifold Sensor -GX9-, REMOVING AND INSTALLING .
12. Charge Air Pressure Sensor -GX26-
    • Consists of:

      Charge Air Pressure Sensor -G31-

      Intake Air Temperature Sensor -G42-

    • Removing and installing. Refer to Charge Air Pressure Sensor -GX26-, REMOVING AND INSTALLING .
13. O-Ring
    • Replace after removing.
14. Air Duct Pipe
    • Removing and installing. Refer to AIR DUCT PIPE, REMOVING AND INSTALLING .
15. Connection
16. O-Ring
    • Replace after removing.
    • Coat before installing with clean engine oil.
17. O-Ring
    • Replace after removing.
    • Coat before installing with clean engine oil.
18. Bolt
    • 7 Nm
    • Thread cutting
    • Position the bolt by hand and tighten it until it finds the old threads, then tighten the bolt to the tightening specification
19. Clip
    • For the air duct pipe
20. Throttle Valve Control Module -GX3-
    • Consists of:

      Throttle Valve Control Module -J338-

      EPC Throttle Drive -G186-

      EPC Throttle Drive Angle Sensor 1 -G187-

      EPC Throttle Drive Angle Sensor 2 -G188-

    • Removing and installing. Refer to Throttle Valve Control Module -GX3-, REMOVING AND INSTALLING .
21. Seal
    • Replace after removing.
22. Seal
    • Replace after removing.
    • Quantity 4

Air Ducts with Screw-Type Clamps, Installing 

Fig 2: Air Guide Hose Clamps Sizes

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Secure all standard production hose clamps. Refer to the Parts Information.

Clamp Tightening Specification 

1. Hose Clamp -a- = 13 mm wide: 5.5 Nm
2. Clamp -b- = 9 mm wide: 3 Nm