Charge Air Cooler

Charge Air Cooler

Special tools, testers and auxiliary items required

• Refractometer (T10007)

• Drip Tray for VAS 6100 (VAS 6208)

• Hose Clip Pliers (VAS 6340)

• Cooling System Charge Unit (VAS 6096)

• Adapter (V.A.G 1274/8)

Removing

- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.

- Remove the noise insulation.

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

- Remove the upper coolant hose - 1 - from the radiator for the charged air coolant circuit by releasing the clip.






- Remove coolant hoses - arrows - from the charge air cooler - 1 - by loosening the hose clamps.






- Remove the bolt - 3 - for the charge air cooler - 1 -.






- Disengage and disconnect connector - 4 -.

- Loosen the clamp - 2 -.

- Remove the bolts - arrows - and then remove the charge air cooler - 1 - from the charge air hose.

- Remove the charge air cooler - 1 - downward from the throttle valve control module.

Installing

Install in reverse order of removal. When doing this note the following:

• Make sure that the charge air cooler and seal are in the correct positions on the throttle valve, refer to => [ Intake Manifold Overview ] Intake Manifold Overview.

- Fill with coolant. Refer to => [ Draining and Filling ] Procedures.

• The hose connections as well as the charge air pipes and hoses must be free of oil and grease before installing.

• Secure hose connections with standard production clamps. Refer to the Parts Catalog.

Tightening Specifications: