Removing and installing exhaust gas recirculation cooler with change-over flap — AUDI

🧭 Before you start

Fits: Audi A8 D3 (4E, 2002–2010)

• Opens: coolant
• Renewed: seals

Don't miss

• Disregard (item 3).
• Renew seals and gaskets. Fit all heat insulation sleeves in the original position when installing.Secure all hose connections with the correct type of hose clips (same as original equipment) Electronic parts catalogue.
• Do not reuse coolant.

🔧 Engine codes this applies to

📋 Procedure

1. Drain off coolant .
2. Remove intake manifold (top section) 23.
3. Lower subframe for repair and assembly work .
4. Remove toothed belt for high-pressure pump 23.
5. Remove high-pressure pump 23.

6. Remove bolts (arrows) and detach bracket for high-pressure pump.
7. Disconnect coolant hose from connections (1) and (2).
8. Loosen sealing cap (arrow) with 32 mm socket.
9. Remove sealing cap together with oil filter element.
10. Pull oil filter element off sealing cap.
11. Unbolt retaining clips (arrows).
12. Spread out rags round oil filter housing to catch escaping oil.
13. Pull out oil filter housing.
14. Remove coolant hose from connection for exhaust gas recirculation (left-side) (arrows).
15. Remove bolts (1) and (2). [Note: Disregard (item 3).]
16. Detach vacuum hose (1).
17. Detach coolant hoses (2) and (3).
18. Remove bolts (arrows) and take off exhaust gas recirculation cooler with change-over flap. [Note: Renew seals and gaskets. Fit all heat insulation sleeves in the original position when installing.Secure all hose connections with the correct type of hose clips (same as original equipment) Electronic parts catalogue.]
19. Install oil filter housing .
20. Install high-pressure pump 23.
21. Install toothed belt for high-pressure pump 23.
22. Install intake manifold (top section) 23. [Note: Do not reuse coolant.]
23. Fill cooling system .

Other AUDI procedures

• Removing and installing engine cover panel – Audi Q7
• Removing and installing charge air cooler (left-side) – Audi
• Renewing engine control unit J623 (master control unit) – Audi
• Removing and installing air mass meter 2G246 (cylinder bank 2)
• Removing and installing charge air cooler (right-side) – Audi
• Removing and installing toothed belt – Audi · 56 torque figures
• Removing engine – Audi A8 D3 · 41 torque figures
• Removing camshaft timing chain from camshafts – Audi A6/A7 C7 · 38 torque figures
• Installing engine – Audi A8 D4 · 36 torque figures
• Removing and installing camshaft timing chain · 29 torque figures