Removing and installing bypass flap with exhaust gas recirculation cooler — VW

🧭 Before you start

Fits: VW Touareg I (7L, 2002–2010)

• Opens: coolant
• Renewed: all seals

🔧 Engine codes this applies to

📋 Procedure

1. Drain coolant .
2. Separate all necessary connectors of engine wiring harness above engine and lay harness to one side.
3. Remove vacuum pipe (A) together with its brackets from intake manifold (arrows).
4. Remove securing pins (arrows) for engine cover panel on both intake manifolds.
5. Unscrew securing bolts (arrows), open clamps and pull off coolant hoses (1) and (2).

6. Remove securing bolt for coolant pipe behind bypass flap (arrow).
7. Pull off coolant hose (2) and lay coolant pipe (1) aside to rear.
8. Unscrew respective two securing bolts (arrow) of connecting pipes for exhaust gas recirculation and remove intake connecting pipes together with intake manifold flap motor (A) and exhaust gas recirculation valve (B) from both intake manifolds.
9. Unscrew securing bolts at connecting pipes for exhaust gas recirculation in area of cylinder head covers and remove their brackets .
10. Completely loosen securing bolt (arrow) of bypass flap, slightly raise bypass flap at rear and remove bolt.
11. Pull bypass flap upwards out of brackets.
12. Guide out bypass flap together with exhaust gas recirculation pipes between engine bulkhead and intake manifolds.
13. Renew all seals and O-rings.
14. Reconnect all lines, hoses and connectors which were separated during removal.
15. Renew hexagon socket head bolt of bracket for vacuum pipe on intake manifold of cylinder bank 2 by a hexagon bolt of the same size and strength rating.
16. Filling cooling system .

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