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:

Noises from shock absorbers
Shock absorbers are often replaced because of noises (rumbling, etc.) experienced by the customer. Inspections on the test rig and in the vehicle have shown that in approx. 70 % of these cases there is no case for complaint. The replacement was not justi ...

Indicator lamps and fuel gauge
Fig. 187 In the instrument cluster: fuel gauge for petrol and diesel First read and observe the introductory information and safety warnings  Lit up Needle position   Possible cause   Solution Red mark ...

General notes concerning repairs to vehicle electrical system
  Caution When batteries are disconnected and reconnected, the procedure described in the workshop manual must be strictly observed.   WARNING ...

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