Audi Workshop Service and Repair Manuals

Removing and installing charge air cooler Special tools and workshop equipment required

t  Fitting sleeve -2033-

t  Assembly device for valves -2036- t  Tyre lever for aluminium rims -V.A.G 1942- Removing l  Supercharger secured to engine and gearbox support -VAS 6095- for assembly work → Chapter.

Charge air cooler (left-side): –  Unclip bracket -1- for vacuum hose.   Note Disregard -item 2-. –  Remove charge pressure sender 2 -G447- → Chapter.

Charge air cooler (right-side): –  Remove throttle valve module -J338- → Rep. gr.24. –  Remove charge pressure sender -G31- → Chapter.

Continuation for both sides: –  Remove bolts -1- and -2- and detach coolant pipes from supercharger.

–  Remove bolts -1, 2- for charge air cooler (left-side) and bolts -3, 4- for charge air cooler (right-side).

–  Attach valve assembly device -2036- with -2036/1- to supercharger, as shown in illustration. –  Apply fitting sleeve -2033- at front of charge air cooler. –  Using tyre lever -V.A.G 1942-, apply moderate pressure and slowly press charge air cooler out of supercharger housing.

Installing l  Tightening torques → Chapter „Charge air coolers - exploded view“   Note t  Renew seals, gaskets, O-rings and self-locking bolts. t  Before assembly, always remove residues from threaded holes in supercharger housing using a thread tap. –  Check gasket -5- on charge air cooler -4-. l  The gasket must not be cracked or damaged. –  Slide gasket -1- onto charge air cooler. –  Insert O-ring -2- into opening in supercharger housing -3-.

–  Coat sealing surface -arrow A- and gasket -arrow B- of charge air cooler -1- with engine oil. –  Also coat sealing surface inside supercharger housing with engine oil.

–  When fitting charge air cooler, make sure that seals align with recesses in supercharger housing -arrows-.   Note

To make it easier to insert and press in the charge air cooler, position the supercharger housing vertically in engine and gearbox support -VAS 6095-.   Caution Risk of damage to charge air cooler. Only insert charge air cooler by hand. –  Insert charge air cooler in supercharger housing -arrow A- by hand as far as stop, letting charge air cooler slide into hole -arrow B- in front of supercharger housing.

–  If necessary, guide charge air cooler by hand via openings -arrows- in supercharger housing when inserting cooler. –  As soon as possible (due to length of bolts), screw in 2 bolts loosely by hand to guide charge air cooler additionally.   Caution Risk of damage to charge air cooler. t  The charge air cooler must not be pulled in by screwing in the securing bolts. t  Insert charge air cooler by hand (without using tools) until sealing flange with gasket makes contact with supercharger housing (maximum: 1 mm distance). Only then tighten bolts, as described in the following.

–  Tighten bolts -1, 2- for charge air cooler (left-side) and bolts -3, 4- for charge air cooler (right-side) in diagonal sequence and in small steps. Remaining installation steps are carried out in reverse sequence; note the following: –  Install coolant pipes on supercharger → Chapter. –  Install throttle valve module -J338- → Rep. gr.24. –  Check supercharger for leaks → Chapter.