Audi Workshop Service and Repair Manuals

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

t  Spring type clip pliers -VAS 5024 A-

Removing –  Drain off coolant → Chapter. –  Pull cover off air duct (release clips on sides) -arrows-.

–  Unclip air duct at the bottom by releasing clips -arrows-. –  Detach air duct (bottom) together with air hose.

–  Unplug electrical connector -1- at air mass meter -G70-. –  Detach vent hose -3- and air hose -2-. –  Unscrew bolt -4- and remove air cleaner housing.

–  Detach hose connection carrier -2- at solenoid valve block by releasing retaining tab. –  Detach vacuum hose -1- at non-return valve for brake servo.

–  Remove bolts -1- and -3-. –  Move vacuum hoses at rear intake pipe clear to one side. –  Disconnect hose -2- for crankcase breather system at air pipe. –  Release spring clip -4- with spring clip pliers -VAS 5024 A- and detach air pipe (rear) at connection on turbocharger.   Note Shown from rear with engine removed for illustration purposes.

–  Detach coolant hoses -1- from exhaust gas recirculation flap. –  Detach coolant hoses -2- and -3- from exhaust gas recirculation cooler. –  Detach vacuum hose -4- from vacuum unit for exhaust gas recirculation change-over flap.

–  Remove bolts -2- and -6-. –  Remove bolts -1, 3, 4, and 5-. –  Remove exhaust gas recirculation cooler with change-over flap. Installing Installation is carried out in the reverse order; note the following:   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. –  Fill cooling system → Anchor. Tightening torques

Component		Nm
Exhaust gas recirculation cooler to bracket		10
EGR connecting pipe to:	Exhaust manifold	25 1)
	Exhaust gas recirculation cooler	22 1)
Air pipe (rear) to bracket		10
l  1) Renew nuts.