Table of contents: Removal ↓ Installation ↓
Removal
Remove the sound insulation. Unscrew nuts "1". For clarity, shown with the engine removed. Bolts "2 and 3" are unscrewed later.
Unscrew the heat shield of the "arrow" turbocharger.
Remove the hood. If present, loosen the bracket. Remove the engine cover "arrows". Remove the sound insulation underneath. Use a screwdriver to lift caps "3" and "4" of the 2-piece wiper arm. Loosen the nuts of both parts of the wiper arm with a few turns. Loosen the arms "1" and "2" of the wiper blades on the axles one by one by lightly rocking them. Completely unscrew the nuts and remove both parts of the wiper arm. If it is not possible to remove the arm in this way, then a standard puller must be used.
Disconnect the washer fluid supply pipe "3". If present, disconnect the plug connectors "4" and "5" of the heated windshield washer nozzles. Loosen the hose clamp "6" using hose clamp pliers "V.A.G 1921" and remove the drain hose from the deflector grille. Remove the rubber seal "1" of the deflector grille. Remove the deflector grille "2".
Loosen the nuts and bolts of the "arrow". Pull the fresh air supply duct forward and remove it, turning it towards the right side of the car.
Remove the air duct hose "3" from the intake manifold flap motor "VI57" by slightly loosening the clamp "2". Disconnect the vacuum hose "1" of the mechanical EGR valve and unfasten it.
Remove the crankcase ventilation hose "4" from the cylinder head cover and put it aside. Ignore pos. "1...3".
Disconnect the plug connector "arrow" of the intake manifold flap motor "VI57". Unscrew the bolts "1...3" and remove the intake manifold flap motor "V157".
Loosen the clamps of the coolant supply hoses to the EGR radiator "3094". Remove the EGR coolant supply hoses "arrows" from the EGR radiator.
Loosen bolts "2 and 3" and remove the EGR radiator. Ignore item "1".
Installation
Installation is in the reverse order, replacing the seals, cuffs and self-locking nuts. The supercharging system must be airtight. The hoses and hose fittings of the air supercharging system must be cleaned of oils and grease before installation. Use clamps of the appropriate series to secure all hose connections. Install the wiper arm.
Tightening torques:
- Heat shield to turbocharger: 22 Nm
- EGR radiator
- 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
[This article was copied from an online resource audimanual.ru]