Volkswagen Golf Service & Repair Manual: Removing and installing charge air cooler

Volkswagen Golf Service & Repair Manual / 4- cylinder injection engine(1.4 1 direct inction. turbocharger) / Exhaust turbocharger, g-charger / Charge air system / Removing and installing charge air cooler

Special tools and workshop equipment required

Hose clamps up to 25 mm -3094-

Removing and installing charge air cooler

Drip tray for workshop hoist -VAS 6208-

Removing and installing charge air cooler

Hose clip pliers -VAS 6362-

Removing

–	Remove radiator cowl → Chapter.

Removing and installing charge air cooler

–	Open clip -1- and push hose -arrow- to one side.

–	Disconnect connector -1-.

Removing and installing charge air cooler

–	Remove air conditioner compressor from bracket -arrows- and tie it up → Air conditioner compressor; Removing and installing air conditioner compressor from and to bracket; Rep. gr.87.

–	Set drip tray for workshop hoist -VAS 6208- underneath.

–	Clamp off coolant hoses at charge air cooler with hose clamps -3094-.

Removing and installing charge air cooler

–	Release hose clips -1- and detach coolant hoses.

–	Remove bolts -arrows-.

Removing and installing charge air cooler

–	Pull charge air cooler -1- evenly towards front (in -direction of arrow-) out of intake manifold.

Installing

Installation is carried out in the reverse order; note the following:

Removing and installing charge air cooler

–	Fit sealing lip -1- in -direction of arrow- onto charge air cooler -2-.

–	Insert new gasket into groove on intake manifold.

Removing and installing charge air cooler

–	Tighten bolts -arrows- alternately and diagonally working from centre outwards.

–	Install hose clips -1-.

Note

If there are minor dents in the fins, refer to → Chapter.

–	Install radiator cowl → Chapter.

–	Check coolant level → Anchor.

Specified torques

→ Chapter „Assembly overview - charge air system“

→ Heating, air conditioning system; Rep. gr.87

Removing and installing charge air cooler

Removing and installing charge pressure sender -GX26-

Charge pressure sender -GX26- consists of Charge air pressure sender -G31- Intake air temperature sender -G42- ...

Checking charge air system for leaks

Special tools and workshop equipment required Charge air system tester -V.A.G 1687- ...

Other materials:

Closing sunroof by hand
Removing – Remove glass panel → Chapter. – If drive is defective, remove glass panel → Chapter. – Pull self-adhesive insulation -3- off. – Remove bolts -2-. ...

Removing and installing defroster flap control motor -V107- with potentiometer -G135-, RHD vehicles
Special tools and workshop equipment required Vehicle diagnostic tester First carry out the following work: – Switch off all electrical consumers. – ...

Changing headlights over from driving on left to driving on right (gas discharge headlights with dynamic high beam control and LED daytime running light)
If a right-hand drive vehicle is driven in a left-hand drive country, or vice versa, the headlights must be converted. This is necessary in order to avoid dazzling oncoming traffic with the asymmetric low beam headlights. Note ...