Withdrawal
Remove soundproofing. Remove nuts -1-.
Loosen bolts -2 and 3- last. Remove heat shield from turbocharger -arrows-. Remove the engine hood.
If present, remove bracket. Remove engine cover -arrows-. Remove the sound insulation underneath. Use a screwdriver to remove caps -3- and -4- from the two-part wiper arm. Loosen the two-piece wiper arm nuts a few turns.
Release levers -1- and -2- by rocking them slightly on the wiper axles. Completely unscrew the nuts and remove the two-piece wiper arm.
Disconnect the washer fluid pipe -3-. Unplug electrical connectors -4- and -5- for heated washer nozzles. Unclip hose clamp -6- using hose clamp pliers -VAG 1921- and detach drain hose from cowling grille. Remove rubber seal -1- for fairing grille. Remove fairing grille -2-.
Remove bolts and nuts -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 -V157- by slightly lifting retainer. Detach vacuum hose -1- from mechanical exhaust gas recirculation valve and place hose to one side.
Disconnect crankcase breather hose -4- from cylinder head and place to one side. Pos. -1...3- ignore.
Unplug electrical connector -arrow- for intake manifold flap motor -VI57-. Release screws -1...3- and remove intake manifold flap motor -V157-.
Clamp off coolant hoses leading to exhaust gas recirculation cooler with hose clamps -3094-. Detach coolant hoses from exhaust gas recirculation cooler.
Remove bolts -2 and 3- and remove exhaust gas recirculation cooler. Pos. -1- ignore.
Unscrew bolts -arrows- and remove intake manifold.
Installation
Install in the reverse order, while it is necessary to replace the gaskets, seals. cuffs and self-locking nuts. The boost system must be airtight. The hose fittings and hoses of the charge air system must be free of oils and grease before installation. Use clamps of the appropriate series to fasten all hose connections. Install the wiper arm.
Tightening torques:
- Intake manifold to cylinder head: 22 Nm
- Heat shield to turbocharger: 22 Nm 1)
- EGR cooler:
- to the mechanical exhaust gas recirculation 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 nuts.
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