Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 708
Installing
Install in reverse order of removal. Note the following:
– If there are small impressions on the fins, pay attention to the
following. Refer to
⇒ “3.5 Cooler and Condenser Assembly”, page 6
.
– Replace the O-rings.
– Place the radiator at an angle in the lower charge air cooler
mount and engage the radiator with each other -arrow-. Pull
to make sure the catch is secure.
– Pivot the charge air cooler with the radiator in the lock carrier.
Pay attention that the radiator mount is seated correctly in the
lock carrier.
– Secure the radiator mount, which was pinched off by the catch
to the lock carrier -arrows- Bolts. Refer to the Parts Catalog.
– Install the front bumper cover. Refer to ⇒ Body Exterior; Rep.
Gr. 63 ; Front Bumper; Bumper Cover, Removing and Instal‐
ling .
– Install the fan shroud. Refer to
⇒ “4.5 Fan Shroud, Removing and Installing”, page 249
– Connect the coolant hose to the coupling. Refer to
⇒ Fig. ““Connect the Coolant Hose to the Coupling”“ ,
Note
♦
All of the coolant must be changed if the radiator was replaced.
♦
The hose connections and charge air system hoses must be
free of oil and grease before installing.
♦
Secure hose connections with standard production clamps.
Refer to the Parts Catalog.
♦
In order to be able to securely mount the charge air hoses on
their connections, the screws on the already used screw-type
clamps must be sprayed with a rust remover before installing.
Tightening Specifications
Bolt
Tightening Specification
Bolted connection to lock
carrier
5 Nm
Tightening Specifications
♦ Refer to
⇒ “4.1 Overview - Radiator/Coolant Fan”, page 244
♦ Refer to
⇒ “2.1 Overview - Charge Air System”, page 264
.
2.4
Charge Air Pressure Sensor - G31- ,
Removing and Installing
Removing
Caution
This procedure contains mandatory replaceable parts. Refer
to component overview prior to starting procedure.
Mandatory Replacement Parts
♦ O-ring - Charge Air Pressure Sensor
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 66 ; Noise Insulation; Overview - Noise Insulation .
– Disconnect the connector -2-.
– Remove the bolts -1- and remove the Charge Air Pressure
Sensor - G31- from the air duct pipe.
Installing
Install in reverse order of removal. Note the following:
Note
Replacing the O-ring.
Tightening Specifications
♦ Refer to
⇒ “2.1 Overview - Charge Air System”, page 264
♦ Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Noise Insulation;
Overview - Noise Insulation .
2.5
Charge Air System, Checking for Leaks
Special tools and workshop equipment required
♦ Turbo System Tester Kit - VAG1687-
♦ Turbo System Tester Kit - Adapter 10 - VAG1687/10-
♦ Turbo System Tester Kit - Adapter - VAG1687/14-
♦ Ultrasonic Tester - VAG1842S-
Procedure
– Loosen the hose clamps -1 and 2- and remove the air guide
pipe.
– Connect the Turbo System Tester Kit - Adapter 10 -
VAG1687/10- with the Adapter - VAG1687/14- to the turbo‐
charger.
– Connect the Turbo System Tester Kit - VAG1687- to the
adapter.
Prepare the Turbo System Tester Kit - VAG1687- as follows:
– Pull the pressure regulating valve -2- upward and remove
completely, close the valves -3 and 4-.
– Connect the Turbo System Tester Kit - VAG1687- to com‐
pressed air -1- with a commercially available adapter piece.
Note
♦
If there is water in the viewing glass, it must be drained through
the drain plug -6-.
♦
Pressure must not exceed 0.5 bar (7.2 psi)!
– Open the valve -3-.
– Set the pressure to 0.5 bar (7.2 psi) using the pressure control
valve -2-.
– Open the valve -4- and wait until the test circuit is filled. Reg‐
ulate the pressure to 0.5 bar (7.2 psi) again if necessary.
– Listen, feel and use commercially available leak detection
spray or the Ultrasonic Tester - VAG1842S- to check the
charge air system for leaks.
Note
♦
A small quantity of air dissipates via valves in engine. A pres‐
sure retention test is not possible for this reason.
♦
Information on the Ultrasonic Tester - VAG1842S- . Refer to
the Operating Instructions.
♦
Release the pressure in the test circuit by pulling off the hose
coupling before removing the adapter.
Assembling
Assembly is performed in reverse order.
3
Special Tools
Special tools and workshop equipment required
♦ Tensioning Strap - T10038-
♦ Turbo System Tester Kit - VAG1687-
♦ Engine Bung Set - VAS6122-
♦ Hose Clip Pliers - VAS6362-
♦ Not Illustrated:
♦ Mini Torque Wrench - VAS6854-
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