Volkswagen Workshop Service and Repair Manuals

Removing and installing charge air cooler (Golf)

Special tools and workshop equipment required

t	Refractometer -T10007-

t	Hose clip pliers -VAS 6340-

t	Torque wrench -V.A.G 1331-

t	Guide rods -T10093-

t	Drip tray for workshop hoist -VAS 6208-

»Carry out the following work sequence« Removing –  Remove front bumper cover → General body repairs, exterior; Rep. gr.63 –  Remove air filter → Chapter. –  Pull connectors off thermal switch and radiator fan. –  Remove radiator → Chapter.   Note To prevent damage to the condenser, make sure that the lines and hoses are not stretched, kinked or bent. –  Remove retaining clamp(s) for refrigerant lines.

–  Make a paper template with the specified dimensions.

–  Fit the template on the plastic bracket at the front right so that it rests against the edges at the top and left. –  Mark the intersection on the template -arrow- with a centre punch. –  Drill a hole into the plastic bracket with a 5-mm drill bit. –  Drill or cut the hole to 16 mm.

–  Unscrew securing bolt -arrow-.

–  Unscrew securing bolts -arrows-. –  Remove charge air cooler downwards. Installing Installation is carried out in the reverse order. When installing, note the following: Specified torques:

Component	Nm
Cowling to radiator	5
Radiator to charge air cooler	5
Charge air cooler to condenser	5