Table of contents: Removal ↓ Installation ↓
Removal
Remove the sound insulation. Unscrew the nuts "1".
Loosen bolts "2 and 3" last. Remove the turbocharger heat shield "arrows". Remove the engine hood.
If present, disconnect the bracket. Remove the "arrow" engine cover. Remove the sound insulation underneath. Use a screwdriver to remove caps "3" and "4" from the two-piece windshield wiper arm. Loosen the two-piece windshield wiper arm nuts a few turns.
Release levers "1" and "2" by slightly rocking them on the wiper axles. Completely unscrew the nuts and remove the wiper arm, which consists of two parts.
Disconnect the windshield washer fluid tube "3". Disconnect the plug connectors "4" and "5" of the heated washer nozzles. Release the hose clamp "6" using hose clamp pliers "V.A.G 1921" and remove the drain hose from the fairing grille. Remove the rubber seal "1" of the fairing grille. Remove the fairing grille "2".
Unscrew the bolts and nuts "arrows". Pull the fresh air duct forward and remove it, turning it towards the right side of the car. Disconnect the air duct hose "3" from the intake manifold flap motor "V157", slightly lifting the retainer. Disconnect the vacuum hose "1" from the mechanical valve of the EGR system and put the hose aside.
Disconnect hose "4" of the engine crankcase ventilation system from the cylinder head 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".
Clamp the coolant hoses leading to the EGR radiator using hose clamps "3094". Remove the coolant hoses from the EGR radiator.
Unscrew bolts "2 and 3" and remove the EGR radiator. Ignore item "1".
Unscrew the "arrow" bolts and remove the intake manifold.
Installation
Installation is in the reverse order, replacing the gaskets, seals and self-locking nuts. The supercharging system must be airtight. The hose fittings and hoses 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:
- Intake manifold to cylinder head: 22 Nm
- Heat shield to turbocharger: 22 Nm 1)
- EGR radiator:
- to mechanical EGR valve: 22 Nm
- to intake manifold: 20 Nm
- to exhaust manifold: 22 Nm 1)
- Intake manifold flap motor "VI57" to mechanical EGR valve: 10 Nm
- Engine cover to bracket: 5.5 Nm
1) Replace the nuts.