Volkswagen Workshop Service and Repair Manuals

Removing and installing exhaust gas recirculation cooler If the exhaust gas recirculation cooler is to be removed or renewed –  First, in the „selection of functions and components “ of a → Vehicle diagnostic tester test pump 2 for coolant circulation -V178-. If coolant circulation pump 2 -V178- is not OK, this may be the cause of the faulty exhaust gas recirculation cooler. Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331-.

t  Lambda probe open ring spanner set -3337-

t  Engine support device -3300 A-

t  Hose clips up to 25 mm Ø -3094-

t  Hose clip pliers -V.A.G 1921 -W00- 0464-

t  Drip tray for workshop hoist -VAS 6208-

t  Used oil collection and extraction unit -V.A.G 1782- »Carry out the following work sequence« Removing

–  Remove engine cover panel → Chapter. –  Remove noise insulation → Rep. gr.50. –  Loosen particulate filter → Chapter.

–  Remove connecting pipes -A- to cylinder head. Golf, Golf Plus –  Air filter housing → Chapter.

–  Remove crankcase breather hose -1-, press release buttons for this. –  Unscrew bolt -2-, swing intake hose and intake suction pipe to rear and pull off of turbocharger.

–  Remove bolts -arrows-. –  Loosen hose clip -1- and remove pulsation damper -2-. –  Oil supply line and oil return line with turbocharger support → Anchor . Passat –  Air filter housing → Chapter.

–  Remove crankcase breather hose -1-, press release buttons for this. –  Unscrew bolt -2-, swing intake hose and intake suction pipe to rear and pull off of turbocharger.

–  Remove bolts -arrows-. –  Loosen hose clip -1- and remove pulsation damper -2-. –  Oil supply line and oil return line with turbocharger support → Anchor . Polo –  Air filter housing → Chapter. –  Drain coolant → Chapter.   Note As it is difficult to gain access to clip on suction hose, it is better to remove intake connecting pipe from turbocharger.

–  Remove crankcase breather hose -3-. –  Pull vacuum hose -2- off suction hose -1- and make accessible. Unclip bracket. –  Completely undo bolt -4- (make sure bolt is captive). –  Unscrew bolt -2-, swing intake hose with intake connection to rear and pull off from turbocharger.

–  Remove bolts -arrows-. –  Loosen hose clip -1- and remove pulsation damper -2-. –  Remove turbocharger support → Chapter „Removing and installing oil supply line and oil return line (turbocharger support) (Polo)“. –  Release front left wheel housing liner at bottom. –  Unscrew bolts of coolant pipes on right → Chapter. –  Remove coolant pipes from exhaust gas recirculation cooler. –  Collect escaping coolant with drip tray for workshop cranes -VAS 6208-. Continuation for all vehicles: –  Catch leaking engine oil with used oil collection and extraction unit -V.A.G 1782-. –  Pull vacuum line off vacuum unit → Item . –  Disconnect electrical connector from exhaust gas recirculation valve -N18- electrical actuator for exhaust gas recirculation cooler. –  Clamp off coolant supply line and return lines using hose clips up to Ø 25 mm -3094- at exhaust gas recirculation cooler → Chapter. –  Disconnect coolant supply line and return lines from exhaust gas recirculation cooler. –  Collect escaping coolant with drip tray for workshop cranes -VAS 6208-. –  Unscrew bolts → Item and remove exhaust gas recirculation cooler. Installing l  Specified torque → Chapter. Installation is carried out in the reverse order; note the following:   Note t  Replace the seals, gaskets and self-locking nuts → Electronic parts catalogue. t  Checking engine oil level → Chapter. t  Replenish coolant → Chapter. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  If particulate filter or pressure differential sender -G 505- is removed and installed, pressure differential sender -G 505- must be adapted using vehicle diagnosis tester: Guided functions; Adapting pressure differential sender -G 505-.