300 TDI Radiator/Intercooler Assembly Dimensions needed

WreckITFrank

WreckITFrank

Technical Excellence Contributor
I am trying to prep to install a new radiator, intercooler, and YRM surround but some of the dimensions are off and trying to see where the issue is. All parts are aftermarket, but the Rad is supposed to be OEM brass tanks, the IC fits fine, so no trouble, but the radiator is too tall, and it flexes the surround when bolted together. Hoping someone has a rad out they can measure, and/or a frame as well.

My radiator top to bottom (not the pegs) is consistently 16 11/16
My side plates, top to bottom are 16 5/8
Inside grommets (where the rad and IC sit are only 16 1/8 between the top and bottom, so the rad needs 9/16 more space...
Trying to find out which is off...I can add pics if it helps. TIA.
 
erover82

erover82

Well-known member
Could sandwich a few washers between the surround plate bolts to make the assembly taller overall.
 
WreckITFrank

WreckITFrank

Technical Excellence Contributor
erover82 said:
Could sandwich a few washers between the surround plate bolts to make the assembly taller overall.
Click to expand...
I was thinking of packing it out. The problem is that I have to slot the e fan shroud to make it fit the bottom... Not a huge deal but wanted to know which part was off.
 
WreckITFrank

WreckITFrank

Technical Excellence Contributor
this drama is solved. I purchased an HD setup from Zach and the radiator fit the YRM frame. The slight mm differences between the rad and the YRM frame added up to be enough of a difference for it not to fit. My rad fits fine in the OEM frame, and the HD rad fits fine in the YRM frame. I will likely soon have an OEM frame, brass tank Rad, and IC to sell. Thanks for the info.
 
rocky

rocky

NAS-ROW Addict
Crazy. Who would have thunk so much trouble getting one of the simplest parts to fit.
 
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