Audi Workshop Service and Repair Manuals

Removing and installing exhaust gas recirculation cooler - vehicles with engine code letters ATL Special tools and workshop equipment required

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

t  Hose clip pliers -VAS 6340-

Removing –  Remove noise insulation -arrows-.

–  Remove nuts -1-.   Note t  Shown in illustration with engine removed. t  The bolts -2 and 3- are removed at a later stage.

–  Remove heat shield for turbocharger -arrows-.

–  Remove bonnet → Chapter. –  If fitted, unclip bracket -1-. –  Take off engine cover panel -arrows-. –  Remove noise insulation beneath cover.

–  Lever off caps -3- and -4- on two-piece windscreen wiper arm with a screwdriver. –  Slacken nuts on two-piece windscreen wiper arm a few turns. –  Release arms -1- and -2- one by one by tilting them slightly on the wiper shafts. –  Remove nuts completely and take off two-piece windscreen wiper arm.   Note Use puller (commercially available) to remove wiper arm if necessary.

–  Disconnect washer fluid hose -3-. –  If fitted, unplug electrical connectors -4- and -5- for heated washer jets. –  Open hose clip -6- using hose clip pliers -V.A.G 1921- and detach water drain hose from cowl panel grille. –  Pull off rubber seal -1- on cowl panel grille. –  Disconnect cowl panel grille -2-.

–  Unscrew nuts and bolts -arrows-. –  Pull fresh air duct forwards and remove by turning it to right side of vehicle.

–  Remove air hose -3- from intake manifold flap motor -V157- by lifting retaining clip -2- slightly. –  Disconnect vacuum hose -1- at mechanical exhaust gas recirculation valve and move vacuum hose aside.

–  Detach crankcase breather hose -4- at cylinder head cover and move clear to one side.   Note Disregard -items 1 ... 3-.

–  Detach electrical connector -arrow- at intake manifold flap motor -V157-. –  Remove bolts -1 … 3- and take out intake manifold flap motor -V157-.

–  Clamp off coolant hoses going to exhaust gas recirculation cooler using hose clamps -3094-. –  Detach coolant hoses -arrow- at exhaust gas recirculation cooler.

–  Remove bolts -2 and 3- and detach exhaust gas recirculation cooler.   Note Disregard -item 1-. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets, seals and self-locking nuts. 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 windscreen wiper arm → Rep. Gr.92. Tightening torques

Component		Nm
Heat shield to turbocharger		22
Exhaust gas recirculation cooler to:	Mechanical exhaust gas recirculation valve	22
	Intake manifold	20
	Exhaust manifold	22
Intake manifold flap motor -V157- to mechanical exhaust gas recirculation valve		10
Engine cover panel to bracket		5.5