Volkswagen Golf Service & Repair Manual: Assembly overview - charge air system

Volkswagen Golf Service & Repair Manual / 4- cylinder injection engine(1.4 1 direct inction. turbocharger) / Exhaust turbocharger, g-charger / Charge air system / Assembly overview - charge air system

Note

Check all air hoses and pipes for firm seating and leaks before carrying out tests or repairs.

Observe rules for cleanliness → Chapter.

Assembly overview - charge air system

1 -	Coolant hose

2 -

Bolt

Thread-forming

Fit and screw in bolt by hand so that it screws into old thread Then tighten bolt to specified torque

15 Nm

3 -	Coolant hose

4 -	Coolant hose

5 -	Charge air cooler

Removing and installing → Chapter

Change coolant after renewing.

6 -	Sealing lip

7 -

Gasket

Renew

8 -	Intake manifold

Removing and installing → Chapter

9 -

Bolt

Specified torque and tightening sequence → Chapter

10 -

O-ring

Renew

11 -	Intake manifold sender -GX9-

Consisting of

Intake air temperature sensor 2 -G299-

Intake manifold pressure sender -G71-

Removing and installing → Chapter

12 -	Charge air pressure sender -GX26-

Consisting of

Charge air pressure sender -G31-

Intake air temperature sender -G42-

Removing and installing → Chapter

13 -

O-ring

Renew

14 -

Air pipe

For removal, use release tools -T10527- and -T10527/1-

15 -

Union

16 -

O-ring

Renew

17 -

O-ring

Renew

18 -

Bolt

Thread-forming

Fit and screw in bolt by hand so that it screws into old thread Then tighten bolt to specified torque

7 Nm

19 -	Retaining clip

For air pipe.

20 -	Throttle valve module -GX3-

Consisting of

Throttle valve module -J338-

Throttle valve drive for electronic power control -G186-

Throttle valve drive angle sender 1 for electronic power control -G187-

Throttle valve drive angle sender 2 for electronic power control -G188-

Removing and installing → Chapter

21 -

Seal

Renew

22 -

Gasket

Qty. 4

Renew

Installing air ducts with screw-type clips

Note

Hose unions and air intake pipes and hoses must be free of oil and grease before installation.

Secure all hose connections with the same type of hose clips as original equipment → Electronic Parts Catalogue.

In order to be able to securely attach the air hoses on their connections, the worm screws of the used hose clips have to be sprayed with penetrating spray before installing.

Specified torque for hose clips

1 -	Hose clip -a- = 13 mm wide: 5.5 Nm

2 -	Hose clip -b- = 9 mm wide: 3 Nm

Assembly overview - charge air system

Charge air system

...

Removing and installing charge pressure sender -GX26-

Charge pressure sender -GX26- consists of Charge air pressure sender -G31- Intake air temperature sender -G42- ...

Other materials:

Removing and installing air intake silencer
Removing – Switch off electrical consumers. – Switch off auxiliary and supplementary heater and switch off ignition. – Remove front part of front right wheel hou ...

Assembly overview - FS III front brake
Note After every brake pad change, depress brake pedal firmly several times with vehicle stationary, so that brake pads are properly seated in their normal operating position. Use the brake filling and bleeding equipment -VAS 5234- to draw off brake ...

Special connector systems
Note If necessary, any housing catches in place (secondary locking mechanisms) must be released or removed prior to disengaging the contacts using the prescribed tool → Chapter. ...