Volkswagen Golf / Golf Plus. Manual - part 330

Installing
– Installation is carried out in the reverse sequence of removal.

Note

Torque setting of pendulum support 

⇒ page 10

 .

1.5

Assembly overview - parts of charge air

cooling

Note

♦

Charge air system must be free of leaks.

♦

When making repairs, remove oil from connection and hose

ends.

♦

All hose connections of charge air system are secured by

spring-type clips or by connector couplings.

♦

Checking charge air system for leaks 

⇒ page 162

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

158

     Rep. Gr.21 - Turbocharging/supercharging

 

Engine codes BLS and BXJ 

⇒ page 160

Installing hose connections with connector couplings

⇒ page 161

1.5.1

Engine codes BJB, BKC, BRU, BXE and BXF

1 - 8 Nm

❑ Fitting location

⇒ page 160

2 - Bracket

❑ Note installation posi‐

tion.

3 - Charge air cooler
4 - Connecting hose
5 - 8 Nm
6 - To turbocharger.
7 - Connecting pipe
8 - To intake connecting pipe.
9 - Vacuum reservoir
10 - 15 Nm
11 - 8 Nm
12 - O-ring

❑ Renew if damaged.

13 - Charge air pressure send‐

er -G31- with intake air tem‐

perature sender -G42-
14 - 3 Nm

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1. Charge air system with turbocharger    

159

 

1 - 8 Nm
Fitting location 

⇒ page 160

2 - Bracket

❑ Note installation posi‐

tion.

3 - Charge air cooler

❑ To remove, bring lock

carrier into service posi‐

tion ⇒  General body re‐

pairs, exterior; Rep. Gr. 

50 ; Body - front; Lock

carrier - service position

4 - Sealing strip

❑ Pushed onto top and

bottom of charge air

cooler

5 - 3 Nm
6 - Charge air pressure sender

-G31- with intake air tempera‐

ture sender -G42-
7 - O-ring

❑ Renew if damaged.

8 - Bracket
9 - 5 Nm
10 - Connecting hose
11 - Charge air pipe
12 - Connecting hose

❑ To intake manifold flap

motor -V157-

❑ Assembly overview - in‐

take manifold 

⇒ page 174

13 - 8 Nm
14 - Connecting hose

❑ To turbocharger.

Securing bolts for charge air cooler
To loosen or tighten securing bolts -arrow-, bumper cover must

be removed.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

160

     Rep. Gr.21 - Turbocharging/supercharging

 

Installing hose connections with connector couplings

⇒ page 161

Hose connections with spring band ring 

⇒ page 162

1.6.1

Installing hose connections with con‐

nector couplings

Caution

The seal in the plug-in connector can be damaged if the se‐

curing clip is in the locked position when fitting the connector.

This can cause leakage. Observe installation instructions.

Removing
– Release plug-in connector by pulling out retaining clip

-arrow-. Separate hose/pipe without tools.

Installing
– If renewed, place seal in groove of charge air hose. Ensure

the seal is correctly seated in the groove.

– Lubricate sealing surface and seal with oil.
– Bring securing clip to release position -1-.
– Push charge air hose into coupling to stop.

– Bring securing clip to locking position -2- and then push charge

air hose again.

– Check if connector coupling seats correctly and is properly

engaged by pulling hose.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1. Charge air system with turbocharger    

161