Volkswagen Workshop Service and Repair Manuals

Removing and installing temperature sensor for exhaust gas recirculation

Special tools and workshop equipment required

t	Hose clips up to 25 mm Ø -3094-

t	Torque wrench -V.A.G 1331-

t	Drip tray -VAS 6208-

t	Spring-type clip pliers -VAS 6362-

t	14 mm socket -T10401 - (not shown)

Prerequisites l  Ignition switched off. l  Engine must be cold. Procedure l  View of vehicle from below: –  Remove noise insulation → General body repairs, exterior; Rep. gr.66. –  Drain coolant → Chapter.   Note To access exhaust gas recirculation temperature sensor -G98-, pull off coolant hoses as shown and move them aside.

–  Separate coolant hoses at both unions -arrow A- and -arrow D-. –  Move both coolant hoses to side -arrow B- and -arrow C-. l  View of engine compartment from above: –  Remove engine cover panel → Chapter.   Caution To prevent damage to the electronic components when disconnecting the battery: Observe notes on procedure for disconnecting the battery.

–  With ignition switched off, disconnect battery earth cable -arrow-. –  Remove air filter housing → Chapter.

–  Remove battery and battery tray -arrows-.

–  Pull connector off exhaust gas recirculation temperature sensor -G98--arrow A- and guide line out.   Note Note installation position of heat shield and routing of wiring.

Figure shows exhaust gas recirculation temperature sensor -G98- from engine compartment, below brake master cylinder from gearbox side -arrow-.

–  Carefully guide 14 mm socket -T10401 - with ratchet extension onto exhaust gas recirculation temperature sensor -G98-.

–  Ensure that cable of exhaust gas recirculation temperature sensor -G98- is routed in groove of 14 mm socket -T10401 --arrow A-. –  Loosen exhaust gas recirculation temperature sensor -G98- and remove it. Installation is performed in the reverse sequence. In the process, note the following:   Note t  Specified torque for exhaust gas recirculation temperature sensor -G98-, 20 Nm. t  If seal is damaged or leaking, nip open and renew. t  Always adhere to specified torques.   Caution Heat shield mats must be reinstalled in original positions. Check all connectors for secure seating. Renew self-locking nuts, seals, gaskets and securing clamps. Hoses are secured with spring-type clips. Spring-type clip pliers -VAS 6362- or hose clip pliers -VAS 6340- are recommended for installation of spring-type clips.