EGR Cooler: Service and Repair

By-Pass Flap and Exhaust Gas Recirculation Cooler, Installing

Special tools, testers and auxiliary items required

• Torque wrench (V.A.G 1331)

• To prevent damage caused by tension, follow the procedure described.

• The following illustrations refer to vehicles with engine code AXR and BSW. On vehicles with engine code BEW, the work procedure is the same, only the intake manifold is somewhat different.

- Attach the by-pass flap - 1 - with a new seal - 2 - and two bolts - 5 - to the Exhaust Gas Recirculation (EGR) cooler - 3 - and hand-tighten these bolts.





- Install the four bolts - 4 - and tighten them to 10 Nm.

- Hand-tighten the Exhaust Gas Recirculation (EGR) cooler - 7 - with the three bolts - 8 - on the intake manifold - 6 - (the exhaust gas recirculation cooler must make contact and be moveable in the threaded connections).





- Install the bolts - 9 - and tighten to 10 Nm.

- Tighten the bolts - 8 - to 10 Nm.

- Hand-tighten the connecting pipe - 14 - the new seals, two bolts - 15 - and bolt - 16 -.





- Hand-tighten the bracket - 12 - with the bolt - 11 - and the bolt - 13 - to the by-pass flap.

- Attache the bracket - 12 - and bolt - 10 - to the intake manifold and tighten the bolt to 10 Nm.

- Tighten the bolt - 11 - to 22 Nm.

- Tighten the bolt - 13 - to 5 Nm.

- Tight the bolts - 15 - and - 16 - to 22 Nm.

- Install the connection pipe - 18 - from the exhaust gas recirculation (EGR) cooler - 16 - to the exhaust manifold - 17 - with the seals, bolts - 20 - and new nuts - 19 -.





- Tighten the bolts - 20 - and nuts - 19 - to 22 Nm.