Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 707
2
Charge Air System
⇒ “2.1 Overview - Charge Air System”, page 264
.
⇒ “2.2 Overview - Charge Air Hose Connections”, page 265
⇒ “2.3 Charge Air Cooler, Removing and Installing”, page 265
.
⇒ “2.4 Charge Air Pressure Sensor G31 , Removing and Instal‐
.
⇒ “2.5 Charge Air System, Checking for Leaks”, page 269
.
2.1
Overview - Charge Air System
Note
♦
Assembly of screw-type clamps for the charge air hose connections. Refer to
⇒ “2.2 Overview - Charge Air Hose Connections”, page 265
.
♦
Before testing or performing a repair, check all air guide pipes and hoses and all vacuum lines for leaks and
secure seating.
♦
Follow the guidelines for clean working conditions. Refer to
⇒ “3.1 Clean Working Conditions”, page 5
1 - Air Guide Pipe
2 - Grommet
3 - Spacer Sleeve
4 - Bolt
❑ 7 Nm
5 - Air Guide Hose
❑ Installing. Refer to
.
6 - Air Guide
7 - Charge Air Cooler
❑ Removing and instal‐
ling. Refer to
8 - Air Guide
9 - Rubber Bushing
❑ For the charge air cooler
10 - Rubber Bushing
❑ For the charge air cooler
11 - Bolt
❑ 7 Nm
12 - Spacer Sleeve
13 - Grommet
14 - Bolt
❑ 5 Nm
15 - Charge Air Pressure Sensor - G31-
❑ Removing and installing. Refer to
⇒ “2.4 Charge Air Pressure Sensor G31 , Removing and Installing”, page 269
.
16 - O-Ring
❑ Replace after removing
17 - Air Guide Hose
❑ Installing. Refer to
⇒ “2.2 Overview - Charge Air Hose Connections”, page 265
18 - Air Guide Pipe
2.2
Overview - Charge Air Hose Connec‐
tions
Installing Hose Connections with Threaded Connections
Note
Tighten the clamps -A- on the charge air pipes to 5.5 Nm. An
insufficient or excessive tightening torque can cause the charge
air hose to come off the charge air pipe while driving.
– Before testing or performing a repair, check all air guide pipes
and hoses and all vacuum lines for leaks and secure seating.
– Clean the hose connections as well as the air guide pipes and
hoses before installing, they must be free of oil and grease.
– Secure hose connections with standard production clamps.
Refer to the Parts Catalog.
– The screws on the used clamps must be sprayed with a rust
remover before installing.
2.3
Charge Air Cooler, Removing and In‐
stalling
Special tools and workshop equipment required
♦ Engine Bung Set - VAS6122-
Caution
This procedure contains mandatory replaceable parts. Refer
to component overview prior to starting procedure.
Mandatory Replacement Parts
♦ O-rings - Charge Air Cooler
Removing
– Remove the fan shroud. Refer to
⇒ “4.5 Fan Shroud, Removing and Installing”, page 249
.
– Remove the radiator. Refer to
⇒ “4.4 Radiator, Removing and Installing”, page 247
.
– Remove the front bumper cover. Refer to ⇒ Body Exterior;
Rep. Gr. 63 ; Front Bumper; Bumper Cover, Removing and
Installing .
– Remove the bolts -1 and 3-.
– Open the retainer in direction of -arrow- and remove the cover
-2-.
– Free up the coolant hose -2-.
– Open the retaining tabs in direction of -arrows-, remove the
upper air duct -1-.
– Remove the left and right bolts -arrow-.
– Unclip the air guide lower section -1- and remove.
– Lift the clamp -arrow- and remove the upper left coolant hose
from the radiator.
– Remove the center guide -A- from the lock carrier -arrows-.
– Remove the left and right radiator mount catches in direction
of -arrows- with a side cutter. Push the upper coolant radiator
slightly to the engine.
Note
The radiator mount with be used again when installing. It is then
attached to the lock carrier. Bolts. Refer to the Parts Catalog.
– Loosen the clamps -1 and 2- and remove the air guide hose.
– Seal the open lines and connections with clean plugs from the
Engine Bung Set - VAS6122- .
– Have a second technician release the retaining clamps -1- in
the direction of -arrow A- . Remove the condenser -3- upward
out of the mounts in direction of -arrows B- .
– Secure the condenser to the lock carrier.
– Remove the charge air cooler downward.
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