Removing and installing exhaust gas recirculation cooler (left-side) — AUDI

Removing and installing exhaust gas recirculation cooler (left-side) on Audi: 16 steps, engines ASE. What to remove, in what order, and what to check.

This procedure removes the left-hand exhaust gas recirculation cooler from the ASE engine in the Audi A8 D3 (4E). Access is from the front, so the lock carrier goes into service position after the coolant is drained, and the left intake manifold and mechanical EGR valve come off. The cooler then unbolts and lifts off the cylinder block before being separated from its connecting flange, which stays on the engine for now. The high-pressure pump bracket and a coolant hose also come off the flange, and the flange itself only needs to come out if the bottom seal is being renewed. On refit, the job ends with the lock carrier, bumper cover, jacking mode off for the air suspension, a coolant fill with fresh coolant and a headlight adjustment check.

16 steps 1 engine code

🧭 Before you start

Drain coolant, put the lock carrier in service position and remove the left intake manifold and mechanical EGR valve. Unbolt and lift off the cooler, separate it from the connecting flange and detach the coolant hose. Rebuild in reverse with new seals, refit the lock carrier and bumper cover, switch off jacking mode, refill the cooling system and check headlight aim.

Fits: Audi A8 D3 (4E, 2002–2010)

Opens: coolant
Renewed: gaskets

Don't miss

The connecting flange stays on the engine unless its bottom seal is being renewed.
Renew gaskets, seals and O-rings; fit original-type hose clips.
Do not reuse the drained coolant.
Deactivate air suspension jacking mode once the car is back together.
Check headlight adjustment after the lock carrier has been refitted.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

ASE

📋 Procedure

Drain coolant .
Move lock carrier to service position .
Remove intake manifold (left-side) 23.
Remove mechanical exhaust gas recirculation valve (left-side) .
Remove bolts (arrows).

ASE? Steps differ between engine variants — check this job against your exact car before you commit to it. Check my car — free →

Lift off cooler (left-side) for exhaust gas recirculation (1) from cylinder block.
Disconnect cooler for exhaust gas recirculation from connecting flange (2). [Note: The connection piece remains on the engine at this stage.]
Remove bracket for high-pressure pump (arrows). [Note: Shown in illustration without connecting flange.]
Detach coolant hose (arrow) from connecting flange. [Note: Remove connecting flange when renewing bottom connecting flange seal.] [Note: Renew gaskets, seals and O-rings. Secure all hose connections with the correct type of hose clips (same as original equipment) Electronic parts catalogue.]
Install mechanical exhaust gas recirculation valve (left-side) .
Install intake manifold (left-side) 23.
Install lock carrier with attachments General body repairs, exterior50.
Install front bumper cover General body repairs, exterior63.
Deactivate jacking mode Running gear, front-wheel drive and four-wheel drive43Operating the air suspension. [Note: Do not reuse coolant.]
Fill cooling system .
Check headlight adjustment 404.

Other AUDI procedures

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TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.

The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.

Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.

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Workshop data on this page last updated 20 Sep 2026.