EGR Cooler: Service and Repair

Exhaust gas recirculation cooler, installing
Special tools and equipment





^ VAG1331 Torque wrench (5 to 50 Nm)

Note: Description of repair must be observed in order to avoid damages caused by stress.





^ Assemble bypass flap -1- with sealing ring -2- and two screws -5- with exhaust gas heat exchanger-3- and tighten these screws.
^ Install four screws -4- and tighten all screws to 10 Nm.





^ Hand-tighten exhaust gas recirculation radiator -7- with three screws -8- to intake manifold -6- (exhaust gas recirculation radiator must lie against and must be moveable in threaded joints).
^ Install screws -9- and tighten to 10 Nm.
^ Tighten bolts/screws -8- to 10 Nm.





^ Hand-tighten connecting pipe -15- with seals, two screws -14- and screw -1 6-.
^ Hand-tighten bracket -12- with screws -11- and -13- to bypass-flap.
^ Install bracket -12- with screw -10- to intake manifold and tighten screw to 10 Nm.
^ Tighten screw -11- to 22 Nm.
^ Tighten screw -13- to 5 Nm.
^ Tighten screws -14- and -16- to 22 Nm.





^ Install connecting pipe -18- from heat exchanger for exhaust gas recirculation -16- to exhaust manifold -17-.
^ Tighten bolts and nuts to 22 Nm.