Removing and installing charge air cooler (Passat) — VW

🧭 Before you start

Fits: VW Passat B6 (3C, 2005–2010), VW Passat B7 saloon (362, 2010–2014), VW Passat B7 Variant (365, 2010–2014)

• Opens: coolant

Don't miss

• Make sure that the coolant lines/hoses are not excessively stretched, kinked or bent.
• Note installation of charge air hoses.

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📐 33 workshop diagrams for AXX

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Remove noise insulation or skit plate General body repairs, exterior 50. Removing and installing noise insulation or skid plate.
2. Remove front bumper General body repairs, exterior 63. Assembly overview - front bumper.
3. Release securing clip on right of charge air cooler in direction of (arrow) and pull off hose (arrow).
4. Release and pull off charge air hose in same way on left-hand side.
5. Loosen hose clip (arrow).

6. Pull off charge air hose (1) on left of charge air cooler (2).
7. Also loosen hose clip on right-hand side and pull off charge air hose.
8. Drain coolant Draining and filling coolant.
9. Remove air filter Removing and installing air filter housing.
10. Release retaining clip (arrow).
11. Pull off coolant hose (1) from radiator.
12. Undo and remove bolts (arrows) of cowling.
13. Release connector (1) and pull off.
14. Remove cowling downwards.
15. Unscrew bolts (arrows).
16. Remove radiator (1) downwards.
17. Undo and remove coolant pump bolts (arrows) of the radiator support.
18. Pull out bottom of radiator from mounting.
19. Tilt radiator backwards. [Note: Make sure that the coolant lines/hoses are not excessively stretched, kinked or bent.]
20. Undo and remove condenser bolts (arrows).
21. Secure condenser to lock carrier.
22. Remove radiator downwards. [Note: Note installation of charge air hoses.]
23. ⚠ The screw-type clips on the charge air pipes must be tightened to 5.5 Nm. If the torque is too low or too high, the charge air hose may slip off the charge air pipe during vehicle operation. — If renewed, place oil seal in groove of charge air hose. Ensure that seal is correctly seated around groove and is not twisted. — 5.5 Nm (4.1 lb-ft)
24. Coat sealing surface and oil seal with oil.
25. Bring retaining clip to release position (1).
26. Push charge air hose into coupling as far as stop.
27. Bring retaining clip to locking position (2) and then press charge air hose again.
28. By pulling on hose, check whether plug-in connector seats correctly and is properly engaged.
29. Electrical connections and routing (see the separate procedure).

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