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:

Removing and installing glove compartment
Special tools and workshop equipment required       Torque wrench -V.A.G 1783- Removing –  Remove dash panel end cover on front passenger side ...

Checking colour indicator, “2-colour”
  WARNING Danger of injury! Observe warning notices and safety regulations → Chapter! General information about colour indicator: The genera ...

Repairs and faults in the airbag system
First read and observe the introductory information and safety warnings Repairs and modifications must always be carried out according to Volkswagen specifications  . Modifications and repairs to the front bumper, the doors, the front seats, the headliner, or the bodywork should be carri ...

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