Exhaust gas recirculation cooler, installing

WARNING: This page is about a different car, the 2006 Volkswagen Golf, 2005 Volkswagen Jetta, 2005 Volkswagen Golf, 2004 Volkswagen Jetta, and 2004 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Special Tool - Torque Wrench V.A.G 1331

GW00000113

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Torque wrench V.A.G 1331

NOTE:

Adhere to the procedure described to prevent damage due to component stress.

Fig 2: Identifying Bypass Flap And EGR Cooler

GW00000415

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Assemble bypass flap - 1 - with seal - 2 - and two bolts - 5 - with EGR cooler - 3 - and tighten by hand.
Insert four bolts - 4 - and tighten all bolts to 10 Nm.

Fig 3: Identifying EGR Cooler And Intake Manifold

GW00000416

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mount EGR cooler - 7 - to intake manifold - 6 - with 3 bolts - 8 - tightened by hand (EGR cooler must make contact and must be able to move within bolt holes).
Insert bolt - 9 - and tighten it to 10 Nm.
Tighten bolts - 8 - to 10 Nm.

Fig 4: Identifying Connecting Pipe And Mounting Hardware

GW00000417

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install connecting pipe - 15 - with seal, two bolts - 14 - and bolt - 16 - hand tight.
Install bracket - 12 - with bolt - 11 - and bolt - 13 - to bypass flap.
Bolt bracket - 12 - with bolt - 10 - to intake manifold and tighten it to 10 Nm.
Tighten bolt - 11 - to 22 Nm.
Tighten bolt - 13 - to 5 Nm.
Tighten bolt - 14 - and - 16 - to 22 Nm.

Fig 5: Identifying Connecting Pipe From EGR Cooler To Exhaust Manifold

GW00000418

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install connecting pipe - 18 - from EGR cooler - 16 - to exhaust manifold - 17 -.
Tighten nuts and bolts to 22 Nm.