Recently replaced my stock intercooler with a new S3/Golf R intercooler. This guide can be used for other brands of intercoolers once they mount the same way as the stock intercooler. Even though these pics may be specific to a Jetta many of the steps are shared amongst other VW and Audi vehicles.

S3/Golf R intercooler:




Useful tools:
Torx screw set including T-25, T-30.
Phllips head screwdriver.
Flat head screwdriver.
Small ratchet type device with socket for varying bits including torx, phillips or flatheads.
Stock VW/Audi wheel bolt tool.



First step would be to remove the upper grille. There are 4 screws: 3 shown in picture. The screw in the white box is duplicated on the other end of the grille. After screws are removed pull the grille out horizontally towards you. May have some resistance as it is held by clips at the bottom.


After removing grille next up is the bumper. Remove two Philips head screws that sit below where the upper grille resides.





Next are 5 screws in each of the wheel wells. 4 highlighted in red here which attach the wheel well guard to the bumper.



And one screw with washer that attaches bumper to fender:





These are the screws with washers needed to attach bumper to fender. Do not mix them up with the other screws during reassembly.



Finally there are 8 screws, highlighted in red, to be removed underneath the car making a total of 20 screws to be removed for the front bumper to come off.








The bumper can be removed now by outwards at the left and right ends to release the bumper from clips then pulling the entire bumper towards you horizontally. Take note of a few things before completely removing bumper: Jettas with front parking sensors and fog lights will have harnesses or wires connected to the bumper which must be disconnected or they will be damaged if bumper is completely pulled off. Two connections shown here. Yellow piece is the back of the foglight with attached wired connection. Other wire connection is the main plug for the front parking sensors.





Foglight on driver side (RHD):


Bumper off. Part highlighted in red is the bumper carrier and bolted onto car's chassis and supports the radiator, intercooler, air conditioner condenser via a large plastic part called the lock carrier. Note the radiator looking object in pic is the air conditioner condenser.