Volkswagen Golf Variant / Jetta. Manual - part 427

 

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Volkswagen Golf Variant / Jetta. Manual - part 427

 

 

❑ With Intake Air Temperature Sensor - G42-

9 - Bolt

❑ 3 Nm

10 - Rubber Grommet

❑ Replace if damaged

11 - Bolt

❑ 8 Nm

12 - Charge Air Pipe

❑ »Cold« side

13 - Connecting Hose

❑ »Hot« side, top
❑ Check for secure fit

14 - From the Turbocharger
15 - Charge Air Pipe

❑ »Hot« side

16 - Connecting Hose

❑ »Hot« side, bottom
❑ Check for secure fit
❑ Replace the seal if it is damaged or if there are leaks.
❑ Connector Coupling Between Charge Air Cooler and Connecting Hose, Disassembling and Assembling.

Refer to

⇒ “4.3 Connector Coupling Between Charge Air Cooler and Connecting Hose, Disassembling and As‐

sembling”, page 291

4.3

Connector Coupling Between Charge

Air Cooler and Connecting Hose, Disas‐

sembling and Assembling

Caution

♦ Follow the safety precautions when working on the charge

air system and turbocharger. Refer to

⇒ “1 Safety Precautions when Working on Charge Air

System And Turbocharger”, page 268

 .

♦ Pay attention to the guidelines for clean working condi‐

tions. Refer to

⇒ “2 Guidelines for Clean Working Conditions”,

page 269

 .

Always pay attention to these instructions before and during

work.

4. Charge Air System    

291

-arrow 1- together.

Note

The clamp -1- can only be completely engaged when the con‐

nector coupling is pressed together.

– Bring the clamp in direction of -arrow 2- into the release posi‐

tion.

– Disconnect the connector coupling without using tools.
Version without Positioning Tab

– Release the connector coupling by pulling the clip -1-. Remove

the hose/pipe -2- without using a tool.

Assembly:
Version with Positioning Tab

Caution

The connector coupling sealing ring can be damaged if the

clamp is in locked position when installing. This would result in

a leak. Follow the assembly instructions.

– Clean the sealing surfaces in the connector coupling.
– When replacing the seal, lay the seal in the groove of the con‐

necting hose. Ensure gasket is completely seated in groove

all the way around.

– Lightly oil the sealing surfaces and the seal.

– Bring the clamp -1- into the release position.
– Slide the connecting hose all the way into the clutch. Pay at‐

tention to the positioning tab -2- while doing this.

– Bring the clamp into the locked position -4-. During this, the

clamp engages in the groove -3-.

– Then press in the connecting hose again.
– Check that the connector coupling is correctly positioned and

locked by pulling on the connecting hose.

Version without Positioning Tab
– When replacing sealing ring, lay ring in charge air hose

groove. Ensure gasket is completely seated in groove all the

way around.

– Oil the sealing surfaces and the gasket.
– Bring the clip into the release position -1-.
– Slide the charge air hose into clutch until it stops.

292

charge air hose back again.

– Check for correct seating and proper locking of connector by

pulling on the hose.

4.4

Charge Air System, Checking for Leaks

Special tools and workshop equipment required
♦ Turbo System Tester Kit - VAG1687- with Turbo System Test‐

er Kit - Adapter 10 - VAG1687/10-

♦ Ultrasonic Tester - VAG1842- or commercially available leak

detection spray

Caution

♦ Follow the safety precautions when working on the charge

air system and turbocharger. Refer to

⇒ “1 Safety Precautions when Working on Charge Air

System And Turbocharger”, page 268

 .

♦ Pay attention to the guidelines for clean working condi‐

tions. Refer to

⇒ “2 Guidelines for Clean Working Conditions”,

page 269

 .

Always pay attention to these instructions before and during

work.

4. Charge Air System    

293

G70- . Loosen the spring clamps using the Hose Clip Pliers -

VAS6362- .

– Insert the Turbo System Tester Kit - Adapter 1 - VAG1687/1-

in the intake hose -1- and secure it with a clamp.

Prepare the Turbo System Tester Kit - VAG1687- as follows:

– Fully turn out the pressure regulator valve -2- to the closed

position and close valves -3 and 4-.

Note

The rotary knob must be pulled upward -arrow- so that the pres‐

sure regulator valve -2- can be turned.

– Connect the Turbo System Tester Kit - VAG1687- to the Turbo

System Tester Kit - Adapter 10 - VAG1687/10- as shown.

294

 

 

 

 

 

 

 

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