Audi Workshop Service and Repair Manuals

Removing and installing exhaust gas recirculation cooler

Removing –  Drain off coolant → Chapter. –  Remove intake manifold (top section) → Rep. gr.23. –  Remove bottom section of intake manifold (left and right) → Rep. gr.23. –  Remove heat shield for turbocharger -arrows-.

Vehicles with 2.7 ltr. engine: –  Remove banjo bolt -2- and disconnect oil supply line from turbocharger.   Note Disregard items marked -1- and -2-.

Vehicles with 3.0 ltr. engine: –  Remove banjo bolt -3- and disconnect oil supply line from turbocharger.   Note Disregard items marked -1- and -2-.

All vehicles (continued): –  Detach hose -arrow-. –  Remove bolts -1 ... 7-.

–  Remove bolt -2- and push coolant pipe (rear) slightly to the side.   Note Ignore items marked -1- and -arrows-. –  Lift off cooler for exhaust gas recirculation (left-side) from cylinder block. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets, seals and O-rings. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. –  Install mechanical exhaust gas recirculation valve  → Chapter. –  Install bottom section of intake manifold (left and right) → Rep. gr.23. –  Install intake manifold (top section) → Rep. gr.23. –  Fill cooling system → Anchor. Tightening torques

Component		Nm
Exhaust gas recirculation cooler to cylinder block		9
Connecting pipe to exhaust gas recirculation cooler		25
Coolant pipe (rear) to cylinder head		9
Crankcase breather pipe to change-over flap for exhaust gas recirculation cooler		9
Heat shield to:	Turbocharger	9
	Cylinder head	9