Volkswagen Golf Service & Repair Manual: Removing and installing charge air cooler
| Special tools and workshop equipment
required |
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| Hose clamps up to 25 mm -3094- |
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| Drip tray for workshop hoist -VAS 6208- |
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| Hose clip pliers -VAS 6362- |
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Remove radiator cowl
→ Chapter. |
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Open clip -1- and push hose
-arrow- to one side. |
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Disconnect connector -1-. |
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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. |
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Set drip tray for workshop hoist -VAS 6208- underneath. |
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Clamp off coolant hoses at charge air cooler with hose
clamps -3094-. |
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Release hose clips -1- and
detach coolant hoses. |
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Pull charge air cooler -1-
evenly towards front (in -direction of
arrow-) out of intake manifold. |
| Installation is carried out in the reverse order; note the
following: |
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Fit sealing lip -1- in
-direction of arrow- onto charge
air cooler -2-. |
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Insert new gasket into groove on intake manifold. |
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Tighten bolts -arrows-
alternately and diagonally working from centre outwards. |
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Install hose clips -1-. |
 Note
| If there are minor dents in the fins, refer to
→ Chapter. |
| – |
Install radiator cowl
→ Chapter. |
| – |
Check coolant level
→ Anchor. |
| → Chapter „Assembly overview - charge air system“ |
| → Heating, air conditioning system; Rep. gr.87 |
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Charge pressure sender -GX26- consists of
Charge air pressure sender -G31-
Intake air temperature sender -G42-
...
Special tools and workshop equipment
required
Charge air system tester -V.A.G 1687-
...
Other materials:
Balancing wheel, checking radial and lateral run-out of wheels and tyres
Before you start balancing the wheels, the following
requirements must be met.
Tyre pressure must be OK.
Tread must not be worn on one side. Tread depth should be at
least 4 mm.
T ...
Checklist
Never carry out any work on the engine or in the engine compartment
if you are not familiar with the requisite procedures and general safety requirements,
or if you only have access to incorrect operating equipment, service fluids,
and unsuitable tools . The work should be carried ou ...
General notes on brake fluid
Note
Only use new brake fluid conforming to VW standard (VW 501 14).
Brake fluid is poisonous. Also due to its corrosive effect
brake fluid must not come into contact with paintwork.
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Removing and installing charge pressure sender -GX26-
Checking charge air system for leaks