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.
|Lower water header tank||16mm|
|Upper water header tank||8mm|
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.