Audi Workshop Service and Repair Manuals

Removing and installing exhaust gas recirculation cooler Special tools and workshop equipment required

t  Drip tray for workshop hoist -VAS 6208-

t  Hose clip pliers -VAS 6362-

Removing –  Lift off engine cover panel (outside -1- and inside -2-) by pulling up evenly.

–  Remove cover -1- over battery; to do so, press release tab -arrow-.

Caution Observe notes on procedure for disconnecting the battery → Rep. gr.27. –  With ignition switched off, disconnect battery earth cable -arrow-.   WARNING Hot steam or hot coolant can escape when expansion tank is opened; cover filler cap with cloth and open carefully. –  Open filler cap on coolant expansion tank. –  Remove particulate filter → Chapter.

–  Unscrew nut -1- and remove bracket with wiring from stud. –  Unclip bracket from wiring harness.

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Lift retaining clip -arrow- and disconnect coolant hose from radiator.

–  Remove bolt -arrow- for air intake pipe (front).

–  Pull cover off air duct (release clips on sides) -arrows-.

–  Release clips on left and right -arrow A- and unclip air duct at bottom -2-. –  Swivel air duct (bottom) slightly to the rear and detach air duct (bottom) from retainers -3-. –  Detach air pipe -1- from air duct (bottom) -arrow B-.

–  Unplug electrical connector -1- at air mass meter -G70-. –  Detach vent hose -3- and air hose -2-. –  Unscrew bolt -4- and remove air cleaner housing.

–  Disconnect coolant hose at bottom of engine oil cooler -arrow- and drain off remaining coolant.

–  Remove battery → Rep. gr.27. –  Remove battery tray -arrows-.

–  Detach crankcase breather hose -2-. –  Move vent hose -4- and vacuum hoses -1- clear at air intake hose. –  Remove bolt -3-. –  Swing air hose to rear and detach from turbocharger.

Vehicles with manual gearbox: –  Detach securing clip -3- for gear selector cable from gearbox selector lever -1- and pull cable off pin -arrow-. Metal gate relay lever: –  Detach securing clip -4- for gate selector cable from gate relay lever -2- and pull cable off pin -arrow-.

Plastic gate relay lever: l  To prevent damage to gate selector cable, cable end-piece must be detached from gate selector cable before removing. –  Pull locking device forwards onto stop -arrow 1- and lock by turning anti-clockwise -arrow 2-. –  Press gate relay lever towards front -arrow 3-.

Vehicles with manual gearbox (continued): –  Remove selector cable support bracket -arrows- from gearbox and place to one side.

All vehicles (continued): –  Remove bolts -arrows-. –  Detach air pipe (left-side) from turbocharger by lifting retaining clips -arrows- slightly. –  Remove air pipe from engine compartment downwards.

–  Unplug electrical connector -2- for exhaust gas temperature sender 1 -G235-.   Note Disregard -items 1, 2, 4-.

–  Detach vacuum hose -2- from vacuum unit for charge pressure control. –  Detach vacuum hose -3- from line going to vacuum unit for change-over flap for exhaust gas recirculation. –  Detach oil supply hose -1- from turbocharger.

–  Detach coolant hose -arrow- at coolant hose/pipe connection.

–  Unplug electrical connector -1- at oil level and oil temperature sender -G266-. –  Unclip bracket -2- at subframe.

Vehicles with auxiliary heater: –  Remove exhaust pipe -3- for auxiliary heater → Rep. gr.82. –  Disconnect coolant pipes going to auxiliary heater from cylinder block together with coolant hoses -1- and -2-.

All vehicles (continued): –  Place drip tray for workshop hoist -VAS 6208- under engine. –  Detach coolant hose -1- at exhaust gas recirculation cooler. –  Unbolt connecting pipe going to exhaust gas recirculation cooler -arrows-.

Vehicles with front-wheel drive: –  Remove nuts -1-, bolt -2- and banjo bolt -3-. –  Remove support for turbocharger together with oil return pipe.

All vehicles (continued): –  Unbolt bracket -2- for particulate filter. –  Detach vacuum line -1- from vacuum unit for change-over flap for exhaust gas recirculation. –  Remove vacuum pipe. –  Remove bolts -arrows- and take off exhaust gas recirculation cooler. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets, seals and self-locking nuts. t  Fill turbocharger with engine oil at connection for oil supply pipe. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. Vehicles with manual gearbox –  Attach and adjust selector mechanism at gearbox → Rep. gr.34. All vehicles (continued): –  Install particulate filter → Chapter. Vehicles with auxiliary heater: –  Install exhaust pipe for auxiliary heater → Rep. gr.82. All vehicles (continued): –  Install air pipes/hoses with plug-in connectors → Chapter. –  Install battery → Rep. gr.27. –  Check oil level → Booklet808. –  Connect coolant hose to radiator → Fig.. –  Fill up with coolant → Anchor.   Note After installing turbocharger, allow engine to idle for approx. 1 minute and do not rev up immediately to ensure turbocharger is supplied with oil. Tightening torques

Component			Nm
Oil return pipe to turbocharger			15
Exhaust gas recirculation cooler to:	Intake manifold		22
	Cylinder block		10
Support for turbocharger to:	Turbocharger		25
	Cylinder block		60
EGR connecting pipe to:	Exhaust gas recirculation cooler		22
	Exhaust manifold		25
Underbody cross member (front) to body			23
Air pipe (left-side) to bracket			8