GReddy Intercooler Kit 98-05 VW GOLF Ⅳ (1.
98-05 VW GOLF Ⅳ (1.8T) Front mount Type31 Installation Manual Please read the entire manual before installing this kit. Application: Make Model Year VW GOLFⅣ Ⅳ 98-05 • • This GReddy Intercooler Kit is designed only for the vehicles specified above. Premium grade gasoline (92 octane or higher) is required with this Kit. Important 1. This installation should only be performed by a trained specialist who is very familiar with the automobile’s mechanical, electrical and fuel management system. 2.
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２．Stock Parts Removal ２－１ Disconnect the negative terminal of the battery. ２－２ Remove the under engine cover. ２－３ Remove the front grill and front bumper. ２－４ Remove the Intercooler hose. ２－５ Remove the Intercooler. ２－５ Remove the pressure sensor from the Intercooler.
３．Kit Installation ３－１ Bumper Reinforcement modification Trim the marked area on the bumper reinforcement as shown. ３－２ Body Modification (1) Cut the shaded area of the body at the left and right front body as shown. ３－３ Body Modification (2) Cut the shaded area of the body at the front body as shown.
３－４ Intercooler installation installation （１） Install the intercooler bracket as shown using the provided spacer between the body and bracket. 〈Parts used ♯１１．１２〉 （２） Install the intercooler to the bracket as shown. 〈Parts used ♯１．１４．１６〉 (3) Install the thrust sensor as shown, using the provided bolt and washer. Adapter ※There are two types of thrust sensors. If the sensor is too small for the hole, use the provided adapter to place in between the sensor and intercooler.
３－５ Intercooler Pipe Installation (1) Install the I-1・I-2・I-3pipe between the turbo and the intercooler using provided hose and hose bands as shown. Ｉ－１ 〈Parts used ♯２．３．４．６．８．９．１０〉 (2) Install the Charge Pressure By-pass Valve using connecting hose. Ｉ－２ ※Cut the connecting hose between charge valve and I-1 by measuring and confirming the necessary length (3) Install the I-2pipe Bracket as shown, using the provided spacer.
３－７ Bumper Modification and Installation (1) Cut the Bumper to clear the Intercooler and Intake pipe. (2) Reinstall the front bumper. ３－８ Starting the Engine （１）Check all the pipe and hose connections, then reconnect the negative side of the battery. （２）Start the engine. While idling, check for any air leaks （３）After inspection, reinstall the front bumper, under cover and other stock parts that was removed. This completes the Intercooler kit installation.
