Audi Workshop Service and Repair Manuals

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

t  Removal lever -80 - 200-

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

t  Drip tray for workshop hoist -VAS 6208-

t  Hose clip pliers -VAS 6362-

Removing –  Remove particulate filter → Chapter. –  Remove air cleaner housing → Rep. gr.23.

–  Remove battery → Electrical system; Rep. gr.27.

–  Remove bolts -arrows- and take out battery tray -1-.

–  Remove nuts -2- and bolts -3-. –  Detach exhaust gas recirculation pipe.   Note Disregard -item 1-. –  Place drip tray for workshop hoist -VAS 6208- beneath engine.

–  Remove bolts -1, 2- and banjo bolt -3-. –  Detach support for turbocharger with oil return pipe.

–  Clamp off coolant hoses using hose clamps -3094-, release hose clips -arrows- and disconnect coolant hoses from exhaust gas recirculation cooler. –  Detach heat insulation sleeve from vacuum unit.

–  Remove bolts -1- for exhaust gas recirculation pipe. –  Disconnect vacuum hose -2- from vacuum unit and move clear. –  Remove bolts -arrows- and detach exhaust gas recirculation cooler. Installing Installation is carried out in the reverse order; note the following: l  Tightening torque → Chapter „Exhaust gas recirculation with exhaust gas recirculation cooler - exploded view“   Note t  Renew gaskets, seals and self-locking nuts. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  Fit heat insulation sleeve in the original position when installing. –  Install support for turbocharger → Chapter. –  Install battery mounting and battery → Electrical system; Rep. gr.27. –  Install air cleaner housing → Rep. gr.23. –  Install particulate filter → Chapter. –  Check coolant level → Anchor.