Removing and installing radiator for charge air cooler — VW

🧭 Before you start

Fits: VW Golf V / Jetta (1K, 2003–2009); platform code AJ5

• Opens: coolant

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• The air conditioner refrigerant circuit must not be opened. — Pull condenser, radiator for charge air cooler and radiator with radiator fans out of lock carrier and support them.
• With a second mechanic, unscrew guide pins T10093 from longitudinal members and carefully remove lock carrier (1). Make sure that all lines are disconnected.
• To prevent damage to condenser or to refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

🔧 Engine codes this applies to

📐 65 workshop diagrams for CAXA

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

📋 Procedure

1. Drain coolant from charge air cooling system .
2. Disconnect coolant hose (quick-release coupling) (arrow) from upper connection of radiator for charge air system.
3. Bring lock carrier into service position General body repairs, exterior50Lock carrier.
4. Separate all electrical line connections leading to lock carrier and add-on parts on lock carrier.
5. Unscrew bolts for radiator for charge air cooler (arrows).

6. ⚠ The air conditioner refrigerant circuit must not be opened. — Pull condenser, radiator for charge air cooler and radiator with radiator fans out of lock carrier and support them.
7. Remove mounting from radiator for charge air cooler.
8. With a second mechanic, unscrew guide pins T10093 from longitudinal members and carefully remove lock carrier (1). Make sure that all lines are disconnected.
9. Remove bolts from radiator.
10. Remove radiator with fan motors from radiator for charge air cooler and support. [Note: To prevent damage to condenser or to refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.]
11. Unscrew bolts (arrows).
12. Remove condenser from radiator for charge air cooler and support.
13. Carefully remove radiator for charge air cooler.
14. Attach lock carrier (1) with a second mechanic. Screw guide pins T10093 into longitudinal members whilst doing this.
15. Fill and bleed cooling system .

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