Intercooler: Service and Repair

Charge Air Cooler

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1783)

• Cable Tie

Removing

- Remove the noise insulation.

- Remove the bumper cover. Refer to "Front Bumper".

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

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






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

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

The Air Conditioning (A/C) condenser pipes are bolted to the right side of the charge air cooler. To remove the bolt, proceed as follows:

- Create a paper template with the specified dimensions.






- Position the template on the right front plastic support so it aligns with the top and left edges.






- Mark the cutting point on the template - arrow - with a punch.

- Drill a hole in the plastic support with a 5 mm drill bit.

- Drill or cut the hold to 16 mm.

- Remove the bolt - arrow - for the A/C condenser pipes.






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






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


To prevent damage to the A/C condenser and the refrigerant lines, do not stretch, kink or bend the pipes and hoses.

• The A/C 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 A/C condenser bolts - arrows - from the charge air cooler.






- Secure the A/C condenser to the lock carrier with cable ties.

- 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.

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