EGR Cooler

Special tools and workshop equipment required 

• Hose clamps up to 25 mm dia. 3094
• Torque Wrench V.A.G 1331
• Torque Wrench V.A.G 1410
• Spring-type clip pliers VAS 5024A
• Drip tray for workshop crane VAS 6208

Removing 

-- Remove the front exhaust pipe FRONT EXHAUST PIPE .

-- Remove the coolant hoses -1- and -3- using hose clamps 3094, as shown -arrows-.

Fig 1: Identifying Coolant Hoses -1- / -3-, Connecting Pipe -2- And Remove Shield -4-

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-- Open and remove the shield -4-.

-- Remove connecting pipe -2-.

-- Remove the bolts -1-, -2- and -4- and remove the complete oil return line -3- from the cylinder block and the turbocharger.

Fig 2: Identifying Bolts -1-, -2-, -4- And Complete Oil Return Line -3-

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-- Remove the pipe/hose line -1-.

Fig 3: Identifying Pipe/Hose Line And Bolts

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

Installing 

Installation is performed in reverse order. When doing this note the following:

-- Install the exhaust gas recirculation cooler with new seals.

-- Install the complete oil return line -3-.

Fig 4: Identifying Bolts -1-, -2-, -4- And Complete Oil Return Line -3-

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-- Replace the bolt -4-.

Tightening specifications TURBOCHARGER ASSEMBLY OVERVIEW .

-- Install the exhaust pipe with the catalytic converter FRONT EXHAUST PIPE .

-- Fill with coolant COOLING SYSTEM, DRAINING AND FILLING .

-- Check the engine oil level ENGINE OIL, CHECKING LEVEL .