Removing and installing exhaust gas recirculation cooler (engine codes BKC, BXE) — VW
Removing and installing exhaust gas recirculation cooler (engine codes BKC, BXE) on VW: 18 steps, engines BKC, BLS, BRM, BXE.
Workshop procedure for VW — the exact step sequence and torque figures, straight from real workshop data.
🧭 Before you start
Fits: VW Golf V / Jetta (1K, 2003–2009)
- Renewed: gaskets
Don't miss
- Hoses (1) to (3) remain connected.
📐 41 workshop diagrams for BKC
Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.
📋 Procedure
- Remove engine cover. [Note: Hoses (1) to (3) remain connected.]
- Detach lines (1) to (3) from air pipe.
- Remove air pipe. Raise retaining clips (1) slightly to do so.
- Disconnect connector (2) at air mass meter G70.
- Detach vent hose (1) and also air duct hoses (3) and (5).
- Unscrew bolt (4) and remove air filter housing with air mass meter and connecting pipe.
- Separate connector (arrow) at intake manifold flap motor V157.
- Unscrew bolts (1) to (3) and remove intake manifold flap motor V157.
- Clamp off and detach coolant hoses (1) and (2) at cooler for exhaust gas recirculation with hose clips up to Ø 25 mm3094.
- Clamp off and detach coolant hoses (1) and (2) with hose clips up to Ø 25 mm3094.
- Detach vacuum hoses (arrow 2).
- Detach vacuum hose (arrow 3) from non-return valve for brake servo.
- Pull vacuum hose (arrow) off tandem pump leading to brake servo.
- Unbolt engine lifting eye at rear of cylinder head (arrow).
- Unscrew bottom connecting pipe from changeover valve for exhaust gas recirculation (arrows).
- Unscrew bolts (arrows).
- Unscrew cooler for exhaust gas recirculation with changeover valve from intake manifold (arrows) and remove. [Note: Renew gaskets, oil seals and self-locking nuts.Observe installation location for intake manifold seal.It is very important to observe notes on installing air pipes with connector .Hose connections must be secured with clamps Electronic parts catalogue.]
- Fill with coolant .
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Ask about your VW BKC — free → or sign up free to see the drawingsOther VW procedures
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Who makes these pages, and how
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.
Seen a figure that does not match your manual? Write to us — we correct it and note when. support@torqfix.com
The story behind TorqFix →Workshop data on this page last updated 20 Sep 2026.