Mk5 Radiator Removal / replacement

[Andy_D]

Evening all,

How difficult a job is this and any specialist tools required?

I have researched with a bit of googling and there are bits and pieces on the web and in other forums but no full guide. Seems like the bumper has to come off (I can handle that) and need to remove some or most of the shrouding around the ac and engine coolant radiators, then I'm not sure if you can lift out or drop it out or if you have to remove some of the ac system etc?

Only other thing to add this is actually for a mk5 gt tsi 170 but I am realistically expecting comments on GTi.

Thanks
 

[GTI-Pirelli]

In short:

- Remove the bumper
- Remove the headlights
- Disconnect the intercooler pipes (Spring clips) located bottom left and right of the Intercooler
- Support the bottom of the Radiator/Intercooler with Jack/Blocks of wood (Do not lift the car - just support the weight)
- Remove the bumper bar (8x large bolts + 2x star head)
- Remove the upper bolts from the slam pannel/radiator mount
- Tip the whole unit forward and remove the coolant pipes (requires a little wiggling) 1x left & 1x right
       MAKE SURE YOU DONT DAMAGE THE AC PIPES (left hand side of the rad when looking in the bay)
- Disconnect the power to the cooling fans (connector above the NS Intercooler pipe)
- Unbolt the cooling fan pack from the radiator (4x bolts) and lift it out
- Unbolt the radiator from the slam pannel (4x bolts)
- Lift the radiator up and out of the top

This is from the Rad change that I did on my GTI last weekend. I would imagine that the TSI isn't too dissimilar.
I hope this helps. Not sure I took too many useful pictures. Will check later.

Good luck. 



-

[Andy_D]

Wow. very useful thanks. 

Am I right in thinking that the AC Condenser / Coolant Radiator and Intercooler are all on the same carrier that you refer to as the "whole unit" and explain can be tipped forward to slide the radiator out?

Would you say allow 4 hours plus?

Weighing up DIY or paying but imagine it won't be cheap even at an indy if it's that lengthy.

Thanks again.

[Llew]

maybe it's different for a tdi but when I had my rad changed two years at a garage I bought it from --they didn't take off the bumper --they did everything from underneath standing in a pit and had it changed it two hours

[Llew]

The garage was in Hounslow by the way

[Andy_D]

Interesting, thanks for info - maybe with a hoist or pit bottom removal is possible - not an option for me though.

Update: Pulled the belly pan of car and leak no where near radiator - just dripping and running along under tray. Actually dripping off bottom of a/c compressor indicating a leak higher up engine. Other than a leaking coolant line somewhere - I suspect water pump which on my model is integral with a clutch control for the super charger. Can't really get enough access so think I am going to have to take it in as it is so tight in there! Will have another look and decide.

For anyone wanting steps and photos of steps to get at radiator this guide to replacing the intercooler looks pretty good - found in last night with more googling!

http://www.forgemotorsport.com/media/FMRADMK5.pdf

PS I had to download the pdf for photos to appear....

Cheers

[homesqueeze]

If you go down the radiator route, I think I paid around £350 to get my GTI one replaced at an indy.