EGR Cooler: Service and Repair

Exhaust Gas Recirculation Cooler, Installing

Special tools, testers and auxiliary items required







- Torque wrench V.A.G 1331

NOTE: Adhere to the procedure described to prevent damage due to component stress.







- Assemble bypass flap - 1 - with seal - 2 - and two bolts - 5 - with EGR cooler - 3 - and tighten by hand.
- Insert four bolts - 4 - and tighten all bolts to 10 Nm.







- Mount EGR cooler - 7 - to intake manifold - 6 - with 3 bolts - 8 - tightened by hand (EGR cooler must make contact and must be able to move within bolt holes).
- Insert bolt - 9 - and tighten it to 10 Nm.
- Tighten bolts - 8 - to 10 Nm.







- Install connecting pipe - 15 - with seal, two bolts - 14 - and bolt - 16 - hand tight.
- Install bracket - 12 - with bolt - 11 - and bolt - 13 - to bypass flap.
- Bolt bracket - 12 - with bolt - 10 - to intake manifold and tighten it to 10 Nm.
- Tighten bolt - 11 - to 22 Nm.
- Tighten bolt - 13 - to 5 Nm.
- Tighten bolt - 14- and - 16 - to 22 Nm.







- Install connecting pipe - 18 - from EGR cooler - 16 - to exhaust manifold - 17 -.
- Tighten nuts and bolts to 22 Nm.