Volkswagen Workshop Service and Repair Manuals

Removing and installing charge air cooler (intake manifold) Special tools and workshop equipment required

t  Hose clip pliers -VAS 6340-

t  Support -3250- Removing –  Remove intake manifold → Chapter.

–  Unscrew securing bolts for charge air cooler in specified sequence -A- to -F-. –  Pull charge air cooler out of intake manifold. Installing   Note Charge air cooler is installed into intake manifold using a workshop press.

–  Push sealing strip -1- in -direction of arrow- onto edge of charge air cooler. –  Check new gasket is seated correctly on intake manifold. –  Push charge air cooler into intake manifold to stop. Do not tilt charge air cooler when installing it.

–  Position support -3250- centrally on charge air cooler. –  Carefully lower ram of workshop press until housing of charge air cooler -1- lies on intake manifold -2-.

–  Screw securing bolts in evenly until bolt heads make contact. –  Tighten securing bolts to 7 Nm in sequence specified -A- to -F-. –  Install intake manifold → Chapter. Further installation is performed in the reverse order of removal.