Exhaust Gas RECIRCULATION Cooler

Removing

-- Drain the coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

-- Remove the upper left coolant pipe. Refer to LEFT UPPER COOLANT PIPE, VEHICLES BUILT THROUGH 05.10 .

-- Remove the right upper coolant pipe. Refer to UPPER RIGHT COOLANT PIPE .

-- Remove the oil filter housing. Refer to OIL FILTER HOUSING .

-- Loosen the clamp -arrow- and remove the exhaust gas recirculation pipe -1-.

Fig 1: Identifying Clamp -Arrow- And Connecting Pipe -1-.

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-- Remove the bolt -1- and the banjo bolt -3- and move the turbocharger oil supply line to the side.

Fig 2: Identifying Bolt -1- And Banjo Bolt -3- And Move Turbocharger Oil Supply Line To Side

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NOTE:

Ignore -2-.

-- Remove the bolts -1- and -2- and then remove the heat shield from the turbocharger.

Fig 3: Identifying Bolts -1 To 2- And Turbocharger Heat Shield

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-- Remove the bolts -2- and -3- and remove the exhaust gas recirculation pipe.

Fig 4: Connecting Pipe And Bolts

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NOTE:

Ignore -1 and 4-.

-- Remove the bolts -arrows- and remove the crankcase ventilation pipe -1- toward the rear.

Fig 5: Identifying Bolts -Arrows- And Crankcase Ventilation Pipe -1-

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-- Remove the connector -2- (orange) for EGR temperature sensor -G98- from the bracket and disconnect it.

Fig 6: Identifying Connectors -1 And 2-

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NOTE:

Ignore -1-.

-- Remove the banjo bolt -1- and bolt -2- and move the coolant line to the side.

Fig 7: Identifying Banjo Bolt -1- And Bolt -2- And Move Coolant Line To Side

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-- Disconnect the connector -1-.

Fig 8: Carefully Pushing Linkage -2- Off Ball Studs -Arrow-

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-- Carefully push the linkage -2- off the ball studs -arrow-.

-- Remove the bolts -3- and then remove the intake flap motor 2 -V275- -4-.

-- Repeat the procedure on the other side of the vehicle.

-- Disconnect vacuum hose -1-.

Fig 9: Coolant Hose, Vacuum Hose And Clamps

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-- Open the clamp -2- and remove the coolant hose.

-- Open the clamp -3- and remove the coolant hose.

-- Remove the bolts -arrows- and then remove the exhaust gas recirculation cooler upward and off the cylinder block.

Installing

Install in reverse order of removal. Note the following:

For the correct tightening specifications, refer to EXHAUST GAS RECIRCULATION OVERVIEW .

NOTE:

Replace seals and O-rings.

Secure all hose connections with hose clamps appropriate for the model.

-- Connect the coolant hose to the coupling. Refer to Fig 10.

Fig 10: Connecting Coolant Hose To Coupling

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-- Install the intake flap motor. Refer to Removal and Installation .

-- Install the coolant pipe. Refer to COOLANT PIPES OVERVIEW .

-- Install the turbocharger heat shield and oil supply line. Refer to TURBOCHARGER OVERVIEW .

-- Install the oil filter housing. Refer to OIL FILTER HOUSING .

-- Remove the right upper coolant pipe. Refer to UPPER RIGHT COOLANT PIPE .

-- Remove the upper left coolant pipe. Refer to LEFT UPPER COOLANT PIPE, VEHICLES BUILT THROUGH 05.10 .

-- Fill with coolant COOLING SYSTEM, DRAINING AND FILLING => Filling .