Removing and installing charge air cooler (Golf und Golf Cabriolet) — VW

🧭 Before you start

Fits: VW Golf V / Jetta (1K, 2003–2009), VW Golf VI (5K, 2008–2013), VW Golf Cabriolet (517, 2011–2016)

• Opens: coolant

Don't miss

• Mark cutting point on template (arrow) by striking with a punch.

🔧 Engine codes this applies to

📐 34 workshop diagrams for BYD

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Remove noise insulation General body repairs, exterior50Noise insulation.
2. Remove bumper cover Bumpers63Removing and installing front bumper cover.
3. Drain coolant .
4. Remove charge air hoses (arrows).
5. Removing fan support .

6. Removing radiator .
7. Make a paper template with the specified dimensions.
8. Fit the template on the plastic bracket at the front right so that it rests against the edges at the top and left.
9. Mark cutting point on template (arrow) by striking with a punch.
10. Drill a hole into the plastic bracket with a 5-mm drill bit.
11. Drill or mill hole out to 16 mm.
12. Unscrew and remove securing bolt (arrow) for condenser pipes.
13. Unscrew bolts (1) for charge air cooler mountings. [Note: The securing bolts of the condenser are difficult to access! With the aid of a 2nd mechanic, lift the charge air cooler out of the radiator mountings. The charge air cooler can now be moved »back and forth« to allow access to the securing bolts.]
14. Unbolt condenser from charge air cooler (arrows).
15. Secure condenser to lock carrier with cable tie.
16. Take out charge air cooler from underneath.

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