Table of contents: Removal ↓ Installation ↓
Removal
Remove the engine hood. Remove the engine cover "arrows".
Remove the noise insulation screen located below; to do this, disconnect the crankcase ventilation hose.
Using a screwdriver, remove caps "3" and "4" from the windshield wiper arms. Loosen the nuts on both arms a few turns. Release arms "1" and "2" by slightly tilting them on the windshield wiper axles. Completely loosen the nuts and remove the windshield wiper arms. Disconnect the windshield washer fluid pipe "3". Disconnect the plug connectors "4" and "5" of the heated washer nozzles. Unclamp the hose clamp "6" using hose clamp pliers "V.A.G 1921" remove the drain hose from the fairing grille. Remove the rubber seal "1" from the fairing grille. Remove the fairing grille "2".
Unscrew the bolts and nuts of the "arrows". Remove the fresh air intake duct and hang it on the right side of the car.
Remove air hose "2" connecting the intercooler and intake manifold. Ignore item "1".
Disconnect vacuum hose "1" from mechanical valve, EGR. Remove vacuum hose "2" from throttle control valve "N₂11".
Clamp the coolant hoses leading to the EGR radiator using hose clamps "3094". Remove the coolant hoses "arrows" from the EGR radiator.
Unscrew bolts "2" and "3", as well as nuts "1", and remove the EGR radiator.
Unscrew the "arrow" bolts and remove the intake manifold.
Installation
Installation is in the reverse order, replacing the gaskets, cuffs and self-locking nuts. The supercharging system must be airtight. The hoses and pipes 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 and adjust the windshield wiper arms.
Tightening torques:
- Intake manifold to cylinder head: 25 Nm
- EGR cooler to mechanical EGR valve: 25 Nm
- EGR cooler to intake manifold: 25 Nm
- EGR cooler to exhaust manifold: 25 Nm 1)
1) Replace the nuts.