VW Golf manuals

Volkswagen Golf Service & Repair Manual: Assembly overview - charge air system

  Note
Check all air hoses and pipes for firm seating and leaks before carrying out tests or repairs.
Observe rules for cleanliness → Chapter.

Assembly overview - charge air system

1 -  Coolant hose
2 -  Bolt
Thread-forming
Fit and screw in bolt by hand so that it screws into old thread Then tighten bolt to specified torque
15 Nm
3 -  Coolant hose
4 -  Coolant hose
5 -  Charge air cooler
Removing and installing → Chapter
Change coolant after renewing.
6 -  Sealing lip
7 -  Gasket
Renew
8 -  Intake manifold
Removing and installing → Chapter
9 -  Bolt
Specified torque and tightening sequence → Chapter
10 -  O-ring
Renew
11 -  Intake manifold sender -GX9-
Consisting of
   Intake air temperature sensor 2 -G299-
   Intake manifold pressure sender -G71-
Removing and installing → Chapter
12 -  Charge air pressure sender -GX26-
Consisting of
   Charge air pressure sender -G31-
   Intake air temperature sender -G42-
Removing and installing → Chapter
13 -  O-ring
Renew
14 -  Air pipe
For removal, use release tools -T10527- and -T10527/1-
15 -  Union
16 -  O-ring
Renew
17 -  O-ring
Renew
18 -  Bolt
Thread-forming
Fit and screw in bolt by hand so that it screws into old thread Then tighten bolt to specified torque
7 Nm
19 -  Retaining clip
For air pipe.
20 -  Throttle valve module -GX3-
Consisting of
   Throttle valve module -J338-
   Throttle valve drive for electronic power control -G186-
   Throttle valve drive angle sender 1 for electronic power control -G187-
   Throttle valve drive angle sender 2 for electronic power control -G188-
Removing and installing → Chapter
21 -  Seal
Renew
22 -  Gasket
Qty. 4
Renew

 
Installing air ducts with screw-type clips
  Note
Hose unions and air intake pipes and hoses must be free of oil and grease before installation.
Secure all hose connections with the same type of hose clips as original equipment → Electronic Parts Catalogue.
In order to be able to securely attach the air hoses on their connections, the worm screws of the used hose clips have to be sprayed with penetrating spray before installing.
Specified torque for hose clips
1 -  Hose clip -a- = 13 mm wide: 5.5 Nm
2 -  Hose clip -b- = 9 mm wide: 3 Nm
 

Assembly overview - charge air system

Charge air system
...

Removing and installing charge pressure sender -GX26-
Charge pressure sender -GX26- consists of Charge air pressure sender -G31- Intake air temperature sender -G42- ...

Other materials:

Removing and installing baffle plate, RHD vehicles
Removing     –  Depending on version, remove plastic bolt or plug -2- and remove baffle plate -1-. Installing –  Install in reverse order ...

Technical data
General repair instructions Repairing electrical wiring harnesses and connectors → Electrical System, General Information; Rep. gr.97 Releasing and dismantling connector housings → Electrical Sys ...

Removing and installing cylinder head
Special tools and workshop equipment required     Socket -3410- Removing   Note Fit all heat shield sleeves in the same place when installing. ...

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