Withdrawal
Remove soundproofing. Remove nuts -1-. Shown with engine removed for clarity. Bolts -2 and 3- are loosened later.
Unscrew heat shield from turbocharger -arrows-.
Remove the hood. If present, unfasten the bracket. Remove engine cover -arrows-. Remove the sound insulation underneath. Pry up caps -3- and -4- of the 2-part wiper arm with a screwdriver. Loosen the nuts on both parts of the wiper arm with a few turns. Loosen windshield wiper arms -1- and -2- on shafts by lightly rocking them one by one. Completely unscrew the nuts and remove both parts of the wiper arm. If it is not possible to remove the lever in this way, then in this case it is necessary to use a standard puller.
Disconnect washer fluid pipe -3-. If fitted, unplug electrical connectors -4- and -5- for heated windshield washer jets. Loosen hose clamp -6- using hose clamp pliers -VAG 1921- and remove drain hose from vent grille. Remove rubber seal -1- from deflector grille. Remove air vent grille -2-.
Remove nuts and bolts -arrows-. Pull the fresh air duct forward and remove it by turning it towards the right side of the vehicle.
Detach air hose -3- from intake manifold flap motor -VI57-; to do this, loosen clamp -2- slightly. Detach vacuum hose -1- for mechanical EGR valve and unclip it.
Detach hose -4- for crankcase breather from cylinder head cover and lay to one side. Pos. -1...3- ignore.
Unplug electrical connector -arrow- for intake manifold flap motor -VI57-. Unscrew bolts -1...3- and remove intake manifold flap motor -V157-.
Unclip coolant hoses at exhaust gas recirculation cooler -3094-. Detach coolant hoses from exhaust gas recirculation cooler -arrows-.
Remove bolts -2 and 3- and remove exhaust gas recirculation cooler. Pos. -1- ignore.
Installation
Reinstall in reverse order, replacing seals, collars and self-locking nuts. The boost system must be sealed. The hoses and hose fittings of the charge air system must be free of oil and grease before installation. Use clamps of the appropriate series to fasten all hose connections. Install the wiper arm.
Tightening torques:
- Heat shield to turbocharger: 22 Nm
- Exhaust gas recirculation cooler
- To mechanical EGR valve: 22 Nm
- Intake manifold: 20 Nm
- Exhaust manifold: 22 Nm
- Intake manifold flap motor -V157- to mechanical EGR valve: 10 Nm
- Engine compartment cover to bracket: 5.5 Nm
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