Passat Wagon L4-1.9L DSL Turbo (AHU) (1997)
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Clean EGR valve shaft using brake cleaner spray (use sparingly and wipe off any residue).
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Apply vacuum until EGR valve opens (audible popping noise heard).
^
The valve plate must lift from the valve seat (observe membrane cam via intake opening)
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Clean EGR valve plate and seat using brake cleaner spray (use sparingly and wipe off any residue).
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Using engine oil, lubricate the EGR valve plate and seat (wipe off excess oil).
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Release vacuum to EGR valve.
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Using engine oil, lubricate the EGR valve shaft (wipe off excess oil).
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Using vacuum pump, manually operate EGR valve several times (make sure shaft is well lubricated).
^
Valve must audibly close (valve plate must position itself again on the valve seat)
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Remove vacuum pump.
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Reinstall vacuum line to EGR valve.
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Reinstall hose from charge air cooler to intake.
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Reinstall engine cover
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Erase DTC memory, road test vehicle for approx. 10 miles (16Km).
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Verify: EGR function, MIL does not come ON and that no DTC's are stored.
When procedure applies to vehicles within
warranty use the following:
Part Identifier:
2639
Labor Operation: 2639511 55 TU