Removing and installing housing with exhaust gas recirculation cooler — AUDI

🧭 Before you start

Fits: Audi A3 (8P, 2003–2012)

• Renewed: gaskets

Don't miss

• Mark installation position of exhaust gas temperature sender 1G235(item 2).

🔧 Engine codes this applies to

📋 Procedure

1. Remove particulate filter .
2. Unplug electrical connector (1) on exhaust gas temperature sensor G98.
3. Remove bolt (1).
4. Mark installation position of exhaust gas temperature sender 1G235(item 2).
5. Unscrew exhaust gas temperature sender 1G235(item 2) from exhaust manifold using a crow foot wrench.

6. Remove nut (3) and bolt (1) and take out control pipe.
7. Remove bolts (1).
8. Remove banjo bolt (3) and detach support for turbocharger with oil return pipe.
9. Clamp off coolant hoses with hose clamps up to 25 mm3094 as shown in illustration.
10. ⚠ Hot steam/hot coolant can escape - risk of scalding.The cooling system is under pressure when the engine is hot.To allow pressure to dissipate, cover filler cap on coolant expansion tank with cloth and open carefully. — Detach coolant hoses from housing for exhaust gas recirculation.
11. Unscrew bolts (1), detach exhaust gas recirculation pipe and remove.
12. Unplug electrical connector (arrow).
13. Remove bolts (2) to (5) and take out housing with exhaust gas recirculation cooler.
14. Detach exhaust gas recirculation cooler from housing. [Note: Renew gaskets, seals and self-locking nuts.Secure all hose connections with the correct type of hose clips (same as original equipment) Electronic parts catalogue.Fit heat insulation sleeve in the original position when installing.]
15. Install support for turbocharger .
16. Install air cleaner housing 23.
17. Install particulate filter .
18. Check coolant level .

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