EGR Cooler, Removing And Installing: Removing

WARNING: This page is about a different car, the 2012 Volkswagen Touareg and 2011 Volkswagen Touareg. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure.

Mandatory Replacement Parts

Sealing Washer - EGR pipe
Clamp - EGR - pipe
O-rings - Turbocharger oil supply line
Gaskets - EGR pipes to Auxiliary EGR cooler
Seal - Crankcase ventilation pipe
O-ring - EGR cooler

-- Drain the coolant. Refer to COOLANT, DRAINING .

-- Remove the upper left coolant pipe. Refer to LEFT UPPER COOLANT PIPE, REMOVING AND INSTALLING .

-- Remove the right upper coolant pipe. Refer to UPPER RIGHT COOLANT PIPE, REMOVING AND INSTALLING .

-- Remove the oil filter housing. Refer to OVERVIEW - ENGINE OIL COOLER, PRESSURE REGULATOR VALVE AND OIL FILTER HOUSING .

-- Remove the pre-catalytic converter. Refer to PRE-CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- 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 -item 2-.

-- Remove the bolts -1-, loosen the bolt -2- and remove the turbocharger heat shield.

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 items -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 orange connector -2- for the EGR Temperature Sensor -G98- from the bracket and disconnect it.

Fig 6: Identifying Connectors -1 And 2-

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NOTE:

Ignore -item 1-.

-- Remove the banjo bolt -1- and screw -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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-- Remove the connector -1-.

Fig 8: Carefully Push The Linkage -2- Off The 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- -item 4-.

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

-- Disconnect the vacuum hose -1-.

-- 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.

Fig 9: Coolant Hose, Vacuum Hose And Clamps

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