Removing and installing exhaust gas recirculation cooler, “single turbo engine” — VW

Removing and installing exhaust gas recirculation cooler,
“single turbo engine”
Special tools and workshop equipment required
Hose clamps up to 25 mm
3094
Torque wrench
V.A.G 1331
Hose clip pliers
VAS 6362
Removing
Assembly overview - charge-air hose connections
Chapter
Note
The exhaust gas recirculation cooler is removed upwards. Contaminated areas must be cleaned thoroughly after installing.
Hose clips are only partly accessible directly and can therefore only be removed using
hose clip pliers
VAS 6340
.
Electrical connector and vacuum hose can only be pulled off exhaust gas recirculation cooler when it has been removed from engine.
To avoid tension or warping, screw in all bolts only loosely at first, and then tighten.
First, align the exhaust gas recirculation cooler and the connecting pipes to each other and fit the bolts by hand. Then tighten the bolts of the exhaust gas recirculation cooler. And then tighten the bolts for the connecting pipes.
Bear in mind different bolt lengths for pipes.
Only screw pipe bolts in loosely at first, then tighten.
Renew gaskets and seals.
The screw-type clip
2
is secured in the pressure hose
1
with
“barbs”
. Only the bolt has to be released.
Open screw-type clip
2
and remove hose
1
.
Release and pull off connector
1
.
Pull wiring harness
3
out of expansion tank
2
.
Unscrew bolts
4
of expansion tank
2
and lay expansion tank aside.
The screw-type clip
2
is secured in the pressure hose
1
with
“barbs”
. Only the bolt has to be released.
Open screw type clip
2
and remove hose
1
.
Clamp off coolant hose
2
with
hose clip up to 25 mm
3094
.
Remove clip
1
and detach coolant hose
2
.
Clamp off coolant hose
2
with
hose clip up to 25 mm
3094
.
Remove clip
3
and detach coolant hose
2
.
Note
Take note of the different bolt lengths for the connecting pipes and the exhaust gas recirculation cooler.
Screw bolts
1
out of connecting pipe
4
.
Pull hose
1
off vacuum unit.
Release and pull off connector
2
.
Unscrew nuts
2
from connecting pipe
3
. Take care not damage
exhaust temperature sender 1
G235
1
in the process.
Unscrew bolts
3
from exhaust gas recirculation cooler
2
.
Note
The bolt 1 at the bottom is difficult to reach. Use a mirror for removing and fitting.
Unscrew bolts
1
from exhaust gas recirculation cooler
2
.
Remove exhaust gas recirculation cooler
2
upwards towards right.
Installing
Installation is carried out in the reverse order; note the following:
Note
To avoid tension or warping, screw in all bolts only loosely at first, and then tighten.
First, align the exhaust gas recirculation cooler and the connecting pipes to each other and fit the bolts by hand. Then tighten the bolts of the exhaust gas recirculation cooler. And then tighten the bolts for the connecting pipes.
Bear in mind different bolt lengths for pipes.
Only screw pipe bolts in loosely at first, then tighten.
Renew gaskets and seals.
Checking coolant level and replenishing coolant
Chapter
.
Specified torques
Chapter
“
Assembly overview - exhaust gas recirculation cooler,
single turbo engine
”