Checking exhaust gas recirculation cooler for leaks, Golf, Golf Plus, Golf Cabriolet, Touran, Passat — VW

🧭 Before you start

Fits: VW Touran I (1T, 2003–2015), VW Passat B6 (3C, 2005–2010), VW Golf VI (5K, 2008–2013), VW Golf Cabriolet (517, 2011–2016), VW Passat B7 saloon (362, 2010–2014), VW Passat B7 Variant (365, 2010–2014)

• Opens: coolant

Don't miss

• When the engine is warm, the cooling system is under pressure.Hot steam/hot coolant can escape - risk of scalding.Cover filler cap on expansion tank with a cloth and open carefully to dissipate pressure. — Open clips (arrow).
• Fill coolant up to »min. mark«(arrow).

🔧 Engine codes this applies to

📋 Procedure

1. Observe safety instructions (see the separate procedure).
2. Observe rules for cleanliness (see the separate procedure).
3. Remove engine cover (see the separate procedure).
4. Remove noise insulation:
5. Checking cooling system for leaks (see the separate procedure).

6. Open plug-in connectors (A) and (B) of fuel lines, and pull off fuel lines. Disconnect plug-in connectors Fuel supply - diesel engines 20. Disconnecting plug-in connectors.
7. ⚠ The fuel line is under pressure. Risk of injury to eyes and skin from fuel. Wear eye protection and protective clothing to avoid eye injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully opening the connection point. — Unclip fuel lines, and move them clear.
8. Lay fuel lines to one side.
9. Release and disconnect connector (3) from pressure differential sender(4).
10. Unclip hoses (2) from retainer.
11. Unscrew securing bolts (1).
12. Lay pressure differential sender(4) to one side. Lines remain connected.
13. Clamp off hose (1) on coolant pipe with hose clamp up to 25 mm 3094.
14. Clamp off coolant hose (1) on coolant circulation pump 2V178(2) with hose clamp up to 25 mm 3094.
15. ⚠ When the engine is warm, the cooling system is under pressure. Hot steam/hot coolant can escape - risk of scalding. Cover filler cap on expansion tank with a cloth and open carefully to dissipate pressure. — Open clips (arrow).
16. Pull coolant hose (2) off coolant pipe (1).
17. Open coolant expansion tank.
18. Hold the hose which has been pulled off into a suitable container.
19. Carefully open hose clamp up to 25 mm 3094 and drain coolant until the coolant expansion tank is empty (see the separate procedure).
20. Connect adapter hose (2) to coolant pipe (1).
21. Secure adapter hose (2) with a hose clip (arrow).
22. Release and disconnect connector (1) from coolant expansion tank (2).
23. Unclip wire (4) from coolant expansion tank (2), and lay it to one side.
24. Remove bolts (3) and remove coolant expansion tank (2).
25. Pull coolant expansion tank (1) upwards, and place it in the vehicle.
26. Clamp off hose (2) with hose clamp up to 25 mm 3094.
27. Open clip, and pull off water hose (3).
28. Clamp off water hose (3) with a hose clamp up to 25 mm 3094.
29. Open coolant expansion tank.
30. Connect adapter hose (3) to the free connection on coolant expansion tank (1).
31. Secure adapter hose (3) with a hose clip.
32. Place coolant expansion tank (1) onto fuel filter (2).
33. Open coolant expansion tank.
34. Fill coolant up to »min. mark«(arrow).
35. Screw adapter for cooling system tester V.A.G 1274/8 into coolant expansion tank.
36. Clamp connector V.A.G 1274 B/1 into adapter for cooling system tester V.A.G 1274/8.
37. Join connection piece V.A.G 1274 B/1 to cooling system tester V.A.G 1274 B using connecting hose supplied.
38. Using hand pump on cooling system tester V.A.G 1274 B, build up a pressure of 1.5 bar.
39. Check hose clamps up to 25 mm 3094 for firm seating, and retighten them if necessary.
40. Repeat pressure loss test (see the separate procedure).
41. The exhaust gas recirculation cooler has a leak. Renew exhaust gas recirculation cooler (see the separate procedure).
42. Install all water hoses, and secure them with hose clips (see the separate procedure).
43. Replenish coolant (see the separate procedure).
44. ⚠ Risk of scalding! Before disconnecting cooling system tester V.A.G 1274 B from the connecting hose or connector V.A.G 1274 B/1, it is essential that the pressure is relieved. To do this, press pressure relief valve on cooling system tester V.A.G 1274 B until pressure gauge displays value of »0«. — Install noise insulation:

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