Upgrade Charge Air Cooler from Crafter 04L145749L -> 04L145749H

[phantom-uk]

When I was looking at it I found a few F coolers for circa £100, the new M&L were about the same and some came with the sensors, they are the same, its just the pipe goes on the front so can use the existing one just take off the metal

I believe you are correct Liz. I also think you can use the two sensors from the F version in the later versions.
Also, the F version sits on an intermediate plate that then gets bolted to a bracket that is bolted onto the cylinder head/camshaft housing, now I believe if you fit an M or L version then you can do away with the intermediate plate so that the replacement cooler bolts directly to the bracket that bolted to the cylinder head/camshaft housing. So you definitely need a few bolts too.
Also, the tech manual states that the two large diameter, extra flexible air hoses (one at the back right and one at the front left, should be replaced after every time they are removed and these are expensive due to they're function. But, having said that, I’ve carefully removed and replaced mine a few times and they’ve been ok. All VW van centre parts departments have the electronic catalogue of parts which tell you which parts you’ll need (and not need) to change from an F version to the M version, if you were to get a list of these parts yourself, you may be in a position to buy an M version (new or second hand), carefully remove the large diameter air hoses, remove the water metal pipe extension you mentioned, remove the intermediate plate, buy some bolts you’ll need, swap the sensors over and you should be good to go.
Let us know how you get on.
Stephen

 

[Jonwm]

I got done over on the new pipes when VW van centre did my glow plugs, they were circa £100 each!

 

[phantom-uk]

I got done over on the new pipes when VW van centre did my glow plugs, they were circa £100 each!

I’ve found that they’re happy to sell you parts but if you ask the servicing/maintenance department for any advice on fitting anythin, they decline to help at all. Having said that, the parts department guy is a font of knowledge and happy to help whenever he can with items needed for a job. Have you had any luck with the buzzing issue Jon?

 

[phantom-uk]

Don’t know what happened there ^ it said you posted the reply to your own comment, not me. lol
Stephen.

 

[Jonwm]

Just keeping on the charge cooler them, seems to have some oil residue building on the side parts, I cleaned it out and its come back. Cant see any cracks, where do we think this is coming from? Its surely just air going through here.

 

[phantom-uk]

Just keeping on the charge cooler them, seems to have some oil residue building on the side parts, I cleaned it out and its come back. Cant see any cracks, where do we think this is coming from? Its surely just air going through here.

View attachment 259965

View attachment 259966

There will be some oil passing through the charge air cooler. This is because the air going into the charge air cooler (large diameter pipe at the rear of the cooler) comes directly from the Turbo, which pushes air containing oil condensate up to the charge air cooler.
When I removed my charge air cooler, there were deposits of oil at the intake and outlet air connections.
I can’t see anywhere else the oil residue would be coming from to end up where it is on the outside of the black plastic element, unless there is a hairline crack in it at that oil residue position.
Being a bit of a “fixer” myself, if there was a crack, I would certainly be tempted to Epoxy/glue/plastic weld the crack before purchasing a new one.

 

[deny_mx]

I finally managed to trace the source of the leak. I installed an EGR blanking plate and drove a few miles, obviously 'off-road.' After removing it and inspecting the EGR cooler, I found it to be very wet. My leak was so slow at one point that I thought it had stopped, but I’ve finally found the source of the problem.