Charge Air Cooler

Charge Air Cooler

Special tools, testers and auxiliary items required

• Seal Installer (2033)

• Adjustable Rod (2036)

• Tire Pry Lever (V.A.G 1942)

• Engine and Transmission Holder (VAS 6095)

Removing

• Securing the supercharger to the (VAS 6095) => [ Supercharger, Securing to Engine and Transmission Holder ] Supercharger, Securing to Engine and Transmission Holder.

Left Charge Air Cooler:






- Unclip the bracket - 1 - for the vacuum hose.

• Ignore - 2 -.

- Remove charge air pressure sensor 2 (G447). Refer to => [ Charge Air Pressure Sensor (G31) and Charge Air Pressure Sensor 2 (G447) ] Service and Repair.

Right Charge Air Cooler:






- Remove the throttle valve control module (J338).

- Remove the charge air pressure sensor (G31). Refer to => [ Charge Air Pressure Sensor (G31) and Charge Air Pressure Sensor 2 (G447) ] Service and Repair.

Continued for Both Sides:






- Remove the bolts - 1 and 2 - and remove the coolant pipes on the supercharger.

- Remove the bolts on the left - 1 and 2 - and right - 3 and 4 - charge air coolers.






- Attach the (2036) to the supercharger with (2036/1) as illustrated.






- Mount the (2033) on the front of the charge air cooler.

- Slowly remove the charge air cooler with even pressure from the supercharger housing using the (V.A.G 1942).

Installing






• For the correct tightening specifications, refer to => [ Charge Air Cooler Overview ] Charge Air Cooler Overview.

• Replace the seals, O-rings and the self-locking bolts.

• Always clean the threaded holes inside the supercharger housing with a thread tap before assembling

- Check the seal - 5 - on the charge air cooler - 4 -.

• The seal must not be cracked or damaged.

- Slide the seal - 1 - onto the charge air cooler.

- Insert the O-ring - 2 - into the opening in the supercharger housing - 3 -.

- Coat the sealing surface - arrow A - and the charge air cooler seal - arrow B - - 1 - with engine oil.






- Coat the inner sealing surface inside the supercharger housing with engine oil.

- Make sure the seals are opposite the openings in the supercharger housing when installing the charge air cooler - arrows -.






• Holding the supercharger housing perpendicular in the (VAS 6095) makes it easier to install and remove the charge air cooler.






Danger of causing damage to the charge air cooler.

• Install the charge air cooler by hand only.

- Install the charge air cooler all the way into the compressor housing by hand - arrow A -. When doing this, let the front of the charge air cooler slide into the hole - arrow B - inside the supercharger housing.

- Manually guide the charge air cooler by hand through the supercharger housing openings - arrows -, if necessary.






- As soon as it is possible, install the 2 bolts loosely by hand to help guide the charge air cooler.

Danger of causing damage to the charge air cooler.

• The charge air cooler may not be installed by using the bolts.

• Install the charge air cooler by hand only until there is a maximum 1 mm between the sealing flange and the seal and the supercharger housing. Only then should the bolts be tightened as follows:

- Tighten the bolts for the left - 1 and 2 - and right - 3 and 4 - charge air coolers in a diagonal sequence and in small steps.






Install in reverse order of removal paying attention to the following:

- Install the coolant pipes to the supercharger. Refer to => [ Compressor Coolant Pipes ] Service and Repair.

- Remove the charge air pressure sensor. Refer to => [ Charge Air Pressure Sensor (G31) and Charge Air Pressure Sensor 2 (G447) ] Service and Repair.

- Install the throttle valve control module.

- Check the supercharger for leaks. Refer to => [ Supercharger, Checking for Leaks ] Testing and Inspection.