VW Golf manuals

Volkswagen Golf Service & Repair Manual: Contact corrosion

Contact corrosion can occur if unsuitable connecting elements (screws, bolts, nuts, washers, etc.) are used.
For this reason, only connecting elements with a special surface coating are fitted in the vehicle.
Moreover, certain rubber or plastic parts as well as adhesives made of electrically non-conductive materials.
If there is any doubt about the suitability of parts, a general rule is to use new parts → Electronic Parts Catalogue.
Routing and securing lines
In order to rule out mix-ups and ensure that lines/wires/cables/hoses/pipe are all installed in their original position, the lines for the fuel, hydraulic systems, vacuum systems and the activated charcoal filter, for example, as well as electrical wires/cables must be marked appropriately before they are removed. If necessary, take a photo or make a sketch.
Because of the lack of space in the engine compartment, make sure that all lines are sufficiently far away from all moving or hot components.

Installing coolers, condensers and radiators

Even if installed correctly, the radiator, the condenser and the charge air cooler may have small dents in their fins. This does not mean that these components have been damaged. It is not permissible to renew radiators, condensers or charge air coolers only because of such minor dents.
   
Rules for cleanliness
When working on the fuel supply and injection system, observe the following “5 rules” for cleanliness: Thoroughly clean all unions and surr ...

Engine assy, cylinder blook, crankcase
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Other materials:

Removing and installing fresh air blower control unit -J126-, RHD vehicles
Removing –  Remove baffle plate → Chapter.     –  Disconnect electrical connectors -1- and -4-. –  Remove bolts ...

Before operating the air conditioning system after recharging with refrigerant
After installing a new air conditioner compressor or filling with fresh refrigerant oil (e.g. after blowing out refrigerant circuit), turn compressor pulley 10 revolutions by hand before starting engine. This will prevent damage to the air conditioner ...

Removing and installing coolant pipes for auxiliary heater
Special tools and workshop equipment required     Torque wrench -V.A.G 1410- (4…20 Nm)   Hose clamps, up to 25 mm -3094- ...

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