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Volkswagen Golf Service & Repair Manual: Removing and installing fresh air intake, LHD vehicles

Volkswagen Golf Service & Repair Manual / Heating, air conditioning / Air conditioner / Air duct / Removing and installing fresh air intake, LHD vehicles

Removing
–  Remove plenum chamber cover → General body repairs, exterior; Rep. gr.50.
–  Remove cover for fresh air intake → Chapter.
–  Remove air quality sensor -G238- (only on vehicles with Climatronic) → Chapter.
   
–  Remove nuts -arrows-.
–  Take the fresh air intake -1- out of the plenum chamber.
Installing
Install in reverse order.
Assembly sequence:
–  Align air intake grille on metal collar.
–  Hold air intake grille and screw on outer nut until it reaches half of welded stud.
–  Screw on nut on opposite side.
–  Tighten outer nut.
–  Tighten centre nut.
  Note
The seal -2- must be properly seated on air intake grille.
Water may ingress into the fresh air intake if the fresh air intake grille is damaged or not properly fitted. This may result in complaints about odours from the heater and air conditioning system and/or about moisture in the vehicle.
Specified torques:
 

Removing and installing fresh air intake, LHD vehicles

Component Specified torque
Nut 3 Nm
 
Assembly overview - air duct and air distribution in passenger compartment
  Note The illustration shows a left-hand drive vehicle.     1 -  Air duct for defroster vent ...

Removing and installing fresh air intake, RHD vehicles
Removing –  Remove plenum chamber cover → General body repairs, exterior; Rep. gr.50. –  ...

Other materials:

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Special tools and workshop equipment required Socket -T10424- Removing –  Remove steering column switch module → Chapter.     ...

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Smooth pipe with a diameter or 5x1 mm or 6x1 mm can be repaired with EPDM hose. –  Cut damaged section at right angles out of smooth pipe which is to be repaired. –  Select the appropr ...

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1 -  Coolant hose 2 -  Coolant pipe Clipped onto intake manifold (bottom) To remove, remove intake manifold → Chapter. 3 -  Bolt 8 Nm 4&nb ...

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