My Aeon GT3
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Day 57 - Plumbing the engine (2)

I got my Bentley service manual for the VW Golf - albeit for 2002 (I couldn't find the 2003 edition on Amazon).

This is a lot easier to understand than the Haynes manual - partly because it's a lot bigger (over 1,000 pages), and also because it is mostly diagrams rather than pictures.

I had this bit left over - it was easy to see in the Bentley manual that it was the lower radiator drain valve.

I also made a note of the engine code - AUQ

This bit is the lower radiator exit pipe

This is the upper radiator exit pipe

This is one of the heater pipes

And this is the other

I thought this was the water pump, but it's actually a secondary air pump. The pipe that's missing goes to the air box, so I could simply replace it with a small air filter.

And these are pipes I don't know where they go. This is part of the air system. I think it connects with the charcoal filter.

These are air pipes

This little box was one of the unidentified parts; I think it's an air reservoir.

These pipes I identified earlier. They're the connections to the water header tank.

With everything labelled either with their purpose, or what they're holding (4 air pipes), I measured the ones I need to get the pipework for.

Engine
Lower water header tank16mm
Upper water header tank8mm
Heater (1)20mm
Heater (2)25mm
Lower radiator32mm
Upper raidator32mm
Windscreen heater
Connection 116mm
Connection 216mm
Radiator
Upper32mm
Lower32mm
Drain valve32mm/32mm
Turbo/Intercooler
Turbo in70mm
Turbo out67mm
Intercooler in57mm
Intercooler out57mm
Inlet manifold67mm

Unfortunately, the drain valve makes it point the wrong direction, so I can't use it.

I've arranged a workshop visit to see what's done on the demonstrator, and also another one they're building. I'll also discuss the intercooler arrangement.

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