Technical Bulletin
Model(s)

Year(s)

Jetta, Jetta
Wagon

2009

Jetta

2010

Eng. Code(s)

Trans. Code(s)

VIN Range From

VIN Range To

All

All

All

All

All

All

All

All

All

All

All

All

All

All

All

2.0L TDI
(CBEA)
2.0L TDI
(CJAA)

Golf, Jetta
SportWagen,
Golf Wagon

2010-2014

Jetta

2011-2014

2.0L TDI
(CJAA)
2.0L TDI
(CJAA)

Beetle, Beetle
Convertible

2.0L TDI
2013-2014
(CJAA)

Condition
21 15 02 January 20, 2014 2025464 Supersedes T. B. V211404 dated May 1, 2014 for labor operation update.
Frozen Charge Air Cooler – Engine Will Not Start
Engine will not start after standing in cold weather below 0°C (32°F), MIL may be illuminated with various induction
and/or boost system faults stored in ECM.

Technical Background
Moisture from the intake air condenses and collects in the charge air cooler. At cold temperatures this moisture
can freeze causing blockage of the intake air system.

Production Solution
None.

Page 1 of 13
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Technical Bulletin
Service
Install revised charge air cooler kit P/N 1K0 198 803B to avoid the formation of this moisture in the boost system.

Procedure
• Lock carrier in service position. See Repair Manual Group 50 in Elsa.
• Separate A/C condenser from charge air cooler.
• Remove radiator and radiator fan assembly.
• Remove the original charge air cooler (item 3 in figure 1) from the vehicle.
Tip:
Charge air hoses can be difficult to remove at the charge air cooler, try separating the hoses from the hot
and cold charge air pipes before loosening charge air cooler.
• Remove the lower charge pressure hoses ( items 4 and 16 in figure 1) and clean of any moisture, ice crystal
formation or sludge. See Repair Manual Group 21, Turbocharger/G-Charger, Description and Operation,
Component Overview, in Elsa.

Figure 1

Page 2 of 13
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Technical Bulletin
• Remove cold side charge air pipe (item 12 in figure 1) and pressure hose to throttle valve (item 7 in figure 1).
• Separate the A/C condenser from the charge air cooler.
• Remove the radiator and radiator fan assembly.
• Separate the charge air pressure sensor –G31-- from cold side charge air pipe.
• Install charge air pressure sensor -G31- from kit to cold side charge air pipe.
• Loosely fit the pressure hose with new temperature switch to the cold side charge air pipe.
Tip:
By loosely installing pressure hose with switch to cold side charge air pipe allows for “wiggle room” when
reinstalling.
• Install the cold side charge air pipe (item 12 in figure 1) and connect the charge air pressure sensor -G31electrical connector.

• Note the vacuum hose routing on the temperature switch (figure
2).
1. Ventilation hose to air cleaner
2. Hose to vacuum source
3. Hose to charge air cooler regulator flap

Figure 2

Page 3 of 13
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Technical Bulletin
• Route vacuum overlay harness as seen in figures 3 and 4.

Figure 3

Figure 4

Figure 5
• Cut ventilation hose to air cleaner where indicated in figure 5.

Page 4 of 13
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Technical Bulletin

Figure 6
• Install splice as indicated in figure 6.
Tip:
Note the white tracer on the vacuum hose in figure 6.

Figure 7
• Cut vacuum source hose where indicated in figure 7, and install splice.
Page 5 of 13
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Technical Bulletin
• Install the revised charge air cooler (item 3 in figure 1) with regulating flap and connect the regulating flap
vacuum hose.
• Re-assemble all charge air pipe connections.
• Connect A/C condenser to charge air cooler using fasteners from kit, and install radiator with fan assembly.
• Reassemble front carrier.
• Re-aim headlights.

Page 6 of 13
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Technical Bulletin
Warranty
Please verify engine code for accurate warranty table selection.

To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and
1)
Procedures Manual
Model(s)

Year(s)

Jetta, Jetta
Wagon

2009

Jetta

2010

Eng. Code(s)

Trans. Code(s)

VIN Range From

VIN Range To

All

All

All

All

All

All

2.0L TDI
(CBEA)
2.0L TDI
(CJAA)
SAGA Coding

Claim Type:

Use applicable Claim Type

1)

Damage
Service Number:

HST

Damage Location
(Depends on Service No.)

--

Use applicable when
indicated in ElsaWeb
(L/R)

Code

2143

0055

Parts Manufacturer

Jetta, Jetta Wagon

3)

21431983 = 20 TU

3)

19701983 = 70 TU

3)

50380950 = 40 TU

3)

63291900 = 70 TU

Labor Operation : Replace Charge Air Cooler
Labor Operation : Remove and Install Radiator
Labor Operation :Lock Carrier Service Position
Labor Operation : Remove and Install Front
Bumper Cover

3ME

2)

OR
63291910 = 90 TU (Cup Edition Only)

3)

Labor Operation : Install Cold Weather Intercooler
Kit

21433199 = 30 TU max.

Page 7 of 13
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Technical Bulletin
Causal Part:

1K0 198 803 B
Diagnostic Time

4)

GFF Time expenditure

01500000 = 30 TU max.

YES

Road Test

01210004 = 10 TU

YES

Technical Diagnosis

01320000 = 00 TU max.

NO

Claim Comment: Input “As per Technical Bulletin 2025464” in comment section of Warranty Claim.
1)

Vehicle may be outside any Warranty in which case this Technical Bulletin is informational only

2)

Code per warranty vendor code policy.

3)

Labor Time Units (TUs) are subject to change with ELSA updates.

4)

Documentation required per Warranty Policy Procedures Manual.

Please verify engine code for accurate warranty table selection.
To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and
1)
Procedures Manual
Model(s)

Year(s)

Golf

2010-2014

Eng. Code(s)

Trans. Code(s)

VIN Range From

VIN Range To

All

All

All

2.0L TDI
(CJAA)
SAGA Coding
Claim Type:

Use applicable Claim Type

1)

Damage
Service Number:

HST

Damage Location
(Depends on Service No.)

--

Use applicable when
indicated in ElsaWeb
(L/R)

Code

2143

0055

Parts Manufacturer
3)

Labor Operation : Replace Charge Air Cooler

Golf

WWO

2)

21431983 = 130 TU

(includes radiator R&I, drain & fill)
Page 8 of 13
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Technical Bulletin
3)

50380950 = 70 TU

3)

63291950 = 40 TU

3)

66051900 = 20 TU

Labor Operation : Install Cold Weather Intercooler
Kit

3)

21433199 = 30 TU max.

Causal Part:

1K0 198 803 B

Labor Operation :Lock Carrier Service Position
Labor Operation : Remove and Install Front
Bumper Cover
Labor Operation : Remove and Install Radiator
Grille

Diagnostic Time

4)

GFF Time expenditure

01500000 = 30 TU max.

YES

Road Test

01210004 = 10 TU

YES

Technical Diagnosis

01320000 = 00 TU max.

NO