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- |
| – |
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. |
| – |
Set drip tray for workshop hoist -VAS 6208- underneath. |
| – |
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:
Removing and installing brake pedal
It is not possible to remove the brake pedal separately.
–
To be able to remove it, pedal cluster/mounting bracket
needs to be removed first
→ Chapter.
Note
Removing brake pedal wi ...
Safety precautions during road tests in which test and measuring equipment
is used
Risk of injury due to unsecured test and measuring equipment
If a front passenger airbag is triggered during an accident,
unsecured test and measuring equipment can become dangerous projectiles.
–
Secure test and measuring equipment with seat belts on ...
Wheel change, installation requirements
Warming cold tyres to minimum installation temperature
Note
This instruction also applies to ultra-high performance
tyres (height/width ratio smaller than/same as 45 % and speed
symbol greater than/same as V).
...
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Removing and installing charge pressure sender -GX26-
Checking charge air system for leaks