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Pelican Technical Article:

Oil Cooler Replacement

Steve Vernon

Time:

2 hours2 hrs

Tab:

$10 to $200

Talent:

***

Tools:

T30 Torx, 13mm socket, 6mm Allen, flathead screwdriver

Applicable Models:

VW GTI (2006-09)

Parts Required:

Oil cooler, gasket

Hot Tip:

Work on a cold engine

Performance Gain:

Engine runs at the proper temperature
With the car safely off the ground you will need to remove the engine tray (red arrow) and right side lower wheel well panel (yellow arrow).
Figure 1

With the car safely off the ground you will need to remove the engine tray (red arrow) and right side lower wheel well panel (yellow arrow). A great many of these car have had the engine trays and front side panels removed over the years and not replaced. If you happen to have a car that still has all the under trays and original hardware please see our article on under tray removal

The charged air pipe and hoses run from the induction system and divert air before it reaches the throttle body (red arrow).
Figure 2

The charged air pipe and hoses run from the induction system and divert air before it reaches the throttle body (red arrow). This charged air runs through a pipe that is secured by an 8mm bolt (blue arrow) and T30 Torx (green arrow) and enters the interior by a quick release fitting (yellow arrow).

With the front of the vehicle removed you can see the components that you will need to remove to get access to the oil cooler.
Figure 3

With the front of the vehicle removed you can see the components that you will need to remove to get access to the oil cooler. Note; you do not need to remove the front of the vehicle to perform this work but if you would like to please see our article on lock carrier removal. You can get to all these components from either above or below with the front of the car attached, though you may want to remove the fans and shroud for a little more space. With the charged air pipe removed (yellow arrow) you will be removing the lower turbo pipe (red arrow) you will need to remove the fasteners (green arrows) for the induction pipe.

On the lower left side unclip the quick release clip from the lower turbo hose and separate the hose from the intercooler (red arrow).
Figure 4

On the lower left side unclip the quick release clip from the lower turbo hose and separate the hose from the intercooler (red arrow). You can leave it attached to the induction pipe and remove it with the pipe or remove it completely now.

Disconnect the wiring connection (red arrow) from the boost sensor (yellow arrow).
Figure 5

Disconnect the wiring connection (red arrow) from the boost sensor (yellow arrow).

Use a flathead screwdriver and loosen the clamp on the throttle body hose (red arrow).
Figure 6

Use a flathead screwdriver and loosen the clamp on the throttle body hose (red arrow).

Working from below remove the T30 screw holding the charged air pipe bracket to the engine (red arrow).
Figure 7

Working from below remove the T30 screw holding the charged air pipe bracket to the engine (red arrow).

Working from the top of the vehicle remove the 13mm nut (red arrow) holding the charged air pipe bracket on and remove the pipe.
Figure 8

Working from the top of the vehicle remove the 13mm nut (red arrow) holding the charged air pipe bracket on and remove the pipe. Use care to wiggle it and the intake hose off the throttle body and out through the bottom of the vehicle.

Pull the wiring loom from the bracket (red arrows).
Figure 9

Pull the wiring loom from the bracket (red arrows).

Use a set of pliers or channel locks and remove the coolant pipe from the front of the oil cooler.
Figure 10

Use a set of pliers or channel locks and remove the coolant pipe from the front of the oil cooler. Even if you have drained the coolant from the vehicle there will be coolant in this hose. Be prepared to catch it and dispose of it properly.

This photo illustrates the oil cooler with the hose detached (red arrow).
Figure 11

This photo illustrates the oil cooler with the hose detached (red arrow). Be prepared for coolant to come out of both the cooler and the hose.

There are four ^mm Allen bolts holding the cooler on (red arrows).
Figure 12

There are four ^mm Allen bolts holding the cooler on (red arrows). The upper two have already been removed and the lower two are difficult to see. Remove the bolts and pull the cooler from the engine. There will be additional coolant and oil in the cooler that will spill out when you remove it so be prepared.

With the cooler removed you can see the back where it mounts to the motor.
Figure 13

With the cooler removed you can see the back where it mounts to the motor. The two red arrows show the oil passages and the yellow arrow shows where the coolant flows to the engine.

With the cooler off you can see where the oil (red arrows) and the coolant (yellow arrow) flow to and from the engine to cooler.
Figure 14

With the cooler off you can see where the oil (red arrows) and the coolant (yellow arrow) flow to and from the engine to cooler.

Remove the old gasket (red arrow).
Figure 15

Remove the old gasket (red arrow). Make sure you get all of the old gasket out of the channels as it gets baked in there over time. Clean everything well and insert the new gasket. Installation is the reverse of removal. Do not forget to top up any lost coolant or oil.

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Comments and Suggestions:
Stan Comments: Is it possible to replace the oil filter housing unit from this position? Most people have said that removing the intake manifold is the only way to do it, but from these pictures it looks like it's accessible once the cooler is off. I have a leak that's running down the front of the oil pan and it looks like this is exactly the spot where it's coming from.

Thanks!
October 20, 2016
  Followup from the Pelican Staff: The article shows it without removing the intake.

Give The Pelican Parts parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 
base Comments: does a 2004 model GOLF 5 GT have a oil cooler?
March 16, 2016
  Followup from the Pelican Staff: It should. The oil filter screws into it. Give our parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 

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Page last updated: Fri 12/2/2016 02:35:54 AM