Audi Workshop Service and Repair Manuals

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

t  Hose clamps for hoses up to 25 mm Ø -3094-

t  Hose clip pliers -VAS 6340-

Removing –  Lift engine cover panel at sides -arrows 1- and pull off towards front -arrow 2-.

–  Detach the hoses/lines -1 ... 3- from air pipe. –  Remove air pipe by lifting retaining clips -arrows- slightly.   Note Leave coolant hose -1- and fuel lines -2- and -3- connected.

–  Unplug electrical connector -2- at air mass meter -G70-. –  Detach vent hose -1- and air hose -3-.

–  Detach electrical connector -arrow- at intake manifold flap motor -V157-. –  Unscrew bolts -1 ... 3- and detach intake manifold flap motor -V157-.

–  Disconnect vacuum hose -3- at exhaust gas recirculation valve -N18-. –  Detach pipe -4- for crankcase breather at air pipe. –  Release hose clip -1- at turbocharger using hose clip pliers -VAS 6340-. –  Move the vacuum hoses clear -arrow-. –  Unscrew bolts -2- and -5- and remove air pipe.

–  Clamp off coolant hoses -1- and -2- at exhaust gas recirculation cooler using hose clamps -3094- and detach.

–  Clamp off coolant hoses -1- and -2- using hose clamps -3094- and detach.

–  Detach hose connection carrier -2- at solenoid valve block by releasing retaining tab. –  Detach vacuum hose -1- at non-return valve for brake servo.

–  Detach vacuum hose -arrow- going to brake servo at tandem pump.

–  Unbolt engine lifting eye at rear on cylinder head -arrow-.

–  Unbolt connecting pipe beneath change-over flap for exhaust gas recirculation -arrows-.

–  Remove bolts -arrows-.

–  Unbolt exhaust gas recirculation cooler (with change-over flap) from intake manifold -arrows- and remove. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets, seals and self-locking nuts. t  Note the installation position of intake manifold gasket. t  Charge air system must be free of leaks. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. –  Install air pipes/hoses with plug-in connectors → Chapter. –  Fill cooling system → Anchor. Tightening torques

Component	Nm
Exhaust gas recirculation cooler to intake manifold	10
Bracket to intake manifold	10
Connecting pipe for exhaust gas recirculation to change-over flap	22
Intake manifold flap motor -V157- to intake manifold	10
Engine lifting eye to cylinder head	22