VW Golf manuals

Volkswagen Golf Service & Repair Manual: 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 ...

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