Exhaust gas recirculation cooler, installing

Special tools, testers and auxiliary items required 

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Torque wrench V.A.G 1331

Fig 2: Identifying Bypass Flap And EGR Cooler

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• 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

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• 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

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• 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

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.