Intercooler: Service and Repair

Charge Air Cooler

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1783)

• Cable Ties

Removing

- Remove the noise insulation.

- Remove the bumper cover.

- Drain the coolant. Refer to => [ Draining and Filling ] Service and Repair.

- Loosen the clamps - arrows - and remove the right charge air hose.






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

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

- Remove the bolts - 2 - from the charge air cooler mounts.

- Push the charge air cooler toward the rear and remove the mounts that are on the side.

- Lift the charge air cooler out of the lower mounting.

- Remove the charge air cooler downward.

Installing


The charge air pipe 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 Cooler Component Overview ] Charge Air Cooler Component 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. Refer to => [ Charge Air Hose and Pipe, Disconnecting and Connecting ] Charge Air Hose and Pipe, Disconnecting and Connecting.

• Install only approved clamps for securing hose connections. Refer to the Parts Catalog.

• Charge air hose connecting and disconnecting, refer to => [ Charge Air Hose and Pipe, Disconnecting and Connecting ] Charge Air Hose and Pipe, Disconnecting and Connecting.