Update from post #386:
I went to the VW dealer this afternoon with the water bottle in hand and pictures (shown above).
I was able to talk to the head shop foreman at the local VW dealership.
He said that he has not seen this before. And wasn't aware of this specific issue. That is probably true since we don't get freezing cold weather here very often.
He then went to the VW tech board and read posts about this issue from other dealerships. He opened a new "ticket" on the tech assistance board with my VIN.
As discussed in this thread, the main theory is that its being caused by the new LP-EGR (low pressure exhaust gas recirc) that is new to the CR TDI engine emissions system.
The exhaust has a high moisture content due to water being one of the products from combustion. This moist LP-EGR air is then condensing in the intercooler in specific conditions. Most commonly in cold weather. Most of the time this is not an issue as the moisture goes through the engine with no issues. BUT, if the moisture freezes in the intercooler lines during cold weather, it will collect, melt, puddle up in the intercooler....then you get what I had this morning.
The VW shop foreman told me the VW tech board says that VW is aware of this issue and that corporate is working on a solution. BUT as of yet, no solution has been released.
The directions to the VW techs are:
1. Drain the intercooler inlet and outlet by removing the hoses (as we on this board are already doing)
2. Dry out intercooler as much as possible with compressed air
3. Engineers at VW are working on solution.
4. No fix yet.
My big concern is that this could destroy an engine very easily. I'm not one to be all drama but I hope VW comes up with a real fix for this soon. I don't want to be buying a new engine after the warranty runs out because this happens again in the future and my engine gets a big slug of water upon start up.