Removing and installing exhaust gas recirculation cooler

Special tools and workshop equipment required

• Torque wrench - V.A.G 1331-.

• Lambda probe open ring spanner set - 3337-

• Hose clamps up to 25 mm - 3094-

• Hose clip pliers -V.A.G 1921 - W00- 0464-

• Drip tray for workshop hoist - VAS 6208-

• Used oil collection and extraction unit - V.A.G 1782-

Removing

• Remove engine cover panel ⇒ 3 Engine cover panel.
• Remove air filter housing with air mass meter - G70- and suction hose ⇒ 7.1 Assembly overview - air filter.

• Unscrew bolt -1-.
• Unclip vacuum line -2- from bracket -arrow- and push it downwards.
• Remove front right wheel.
• Remove front right wheel housing liner ⇒ General body repairs ⇒ Rep. gr. 66.
• Remove noise insulation ⇒ Rep. gr. 50.
• Remove particulate filter ⇒ 2.1.2 Assembly overview - particulate filter (RHD).

• Remove connection pipe -2- leading to cooler for exhaust gas recirculation.
• Unscrew connecting pipe -1- only at exhaust gas recirculation cooler -arrows-.
• Catch leaking engine oil with used oil collection and extraction unit - V.A.G 1782-.

• Undo union nut -1- with 17 mm open-end ring spanner.
• Unscrew bolts -2, 3, 5 and 6-.
• Detach oil supply line -7-.
• Pull turbocharger support -4- off the oil return line -8-.
• Remove heat shielding covering at vacuum unit.
• Pull vacuum line off vacuum unit.
• Pull connector off exhaust gas recirculation actuator - V338-.
• Pinch off coolant hoses leading to exhaust gas recirculation cooler using hose clamps, up to 25 mm - 3094-.
• Collect escaping coolant with drip tray for workshop hoists - VAS 6208-.
• Pull coolant hoses off exhaust gas recirculation cooler.
• Unscrew bolts and remove exhaust gas recirculation cooler.

Installing

Specified torques ⇒ 3 Exhaust gas recirculation.

• Installation is carried out in the reverse order; note the following:

• Add coolant ⇒ 1.3.1 Draining.
• Checking engine oil level ⇒ 1.3 Removing and installing sump.