Charge Air Cooler

Charge Air Cooler

Special tools, testers and auxiliary items required

• Torque wrench 5-60 Nm (VAG 1783)

Removing

- Remove the noise insulation.

- Remove the bumper cover.

- Drain the cooling system. Refer to --> [ Draining and Filling ] [1][2]Cooling System, Draining and Filling.

- Remove the right charge air hose - arrows -.





- Remove the fan shroud. Refer to --> [ Fan Shroud ] Fan Shroud.

- Remove the radiator. Refer to --> [ Radiator ] Radiator.

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





• The condenser bolts are difficult to access. With the help of a second technician, lift the charge air cooler out of the lower mounts. Now the charge air cooler can be tilted back and forth and the bolts are accessible.

- Remove the condenser pipes on the right side of the charge air cooler - arrow -.





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





- Secure the condenser to the lock carrier with cable ties.

- Remove the charge air cooler downward.

Installing

CAUTION!
The charge air hose 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 System Assembly Overview ] Charge Air System Assembly 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 --> [ Charge Air Hose Connector Coupling, Disconnecting and Connecting ] Charge Air Hose Connector Coupling, Disconnecting and Connecting.

• Secure all hose connections using hose clamps appropriate for the model type.

• Assemble the charge air hose connections. Refer to --> [ Charge Air Hose Connector Coupling, Disconnecting and Connecting ] Charge Air Hose Connector Coupling, Disconnecting and Connecting.