Bypass Flap and Exhaust Gas Recirculation Radiator, Assembling

Bypass Flap And Exhaust Gas Recirculation Radiator, Assembling

Special tools, testers and auxiliary items required







- Torque wrench V.A.G1331

NOTE:
- Description of work must be observed in order to avoid damage caused by stress.
- The following illustrations refer to vehicles with engine code AXR. For vehicles with engine code BEW the work sequence is the same, only the intake manifold is slightly different.







- Assemble bypass flap -1 - with seal - 2 - and two bolts - 5 - together with exhaust gas recirculation cooler - 3 - and tighten these bolts by hand.
- Fit four screws - 4 - and tighten all screws to 10 Nm.







- Fit exhaust gas recirculation cooler - 7 - on intake manifold - 6 - hand-tight using three bolts - 8 - (exhaust gas recirculation cooler must lie against and must be moveable in threaded joints).
- Install bolts - 9 - and tighten to 10 Nm.
- Tighten bolts/screws - 8 - to 10 Nm.







- Hand-tighten connecting pipe -14 - with seals, two bolts -14 - and bolt -16-.
- Hand-tighten bracket -12 - with bolts -11 - and -13 - to bypass flap.
- Fit bracket -12 - with bolt -10 - to intake manifold and tighten bolt to 10 Nm.
- Tighten bolt -11- to 22 Nm.
- Tighten bolt -13 - to 5 Nm.
- Tighten bolts -15 - and -16 - to 22 Nm.







- Install connecting pipe -18 - from heat exchanger for exhaust gas recirculation -16 - to exhaust manifold -17 - with seals, bolts - 20 - and new nuts -19 -.
- Tighten bolts - 20 - and nuts -19 - to 22 Nm.