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”“ ,

page 245

 .

– Fill with coolant. Refer to 

⇒ page 222

 .

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-