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Exhaust System - CDCA CDBA CNEA CSHA CNFA CNFB - PDF Download

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68 views30 pages

Exhaust System - CDCA CDBA CNEA CSHA CNFA CNFB - PDF Download

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Haji Rashid
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Amarok 2011 > 4-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 wa Exhaust system 1 Exhaust pipes, silencers 21.4 Assembly overview silencers’, page 374 = "1.2 Checking exhaust system for leaks’, page 375 = 1.3 Aligning exhaust system free of stress”, page 375 44 Assembly overview - silencers 1. Screwstype clip D_ Note installation posi- tion, 0 35Nm 2 - Rubber mounting D_ Note installation posi- tion > page 375 3 - Front silencer Removing: — Remove front propshaft. — Remove gearbox sup- port and gearbox mountings = page 34 = Detach frontirear silenc- ers at separating point — Undo bolts holding hanger > Item 6 (page 374) on gearbox cross member. = Detach front ilencer from rubber mounting = Item 2 (page 374) and completely remove front sllencer. 4 Rear silencer Removing: = Detach front ahd rear si- lencers at separating point. = Detach rear silenéer from rubber mounting = Item 2 (page 374) and completely remove rear silencer. 5 - Double clamp Q Note installation position. a Installation of double clamp = pagé’37S. 31Nm 6 - Mounting Fasten mounting on gearbox cross member = page 375 374 ep. o126-- Exhaust systom cylinder diesel engine (2.0 | engine, 7- Bolt Q 20Nm Fasten mounting on gearbox cross member = Secure mounting -2: to gearbox cross member -1- with bolts 23. Installation of double clamp — Mark the distances 39 mm -a and b- at end of pipe of front silencer -2- and beginning of pipe of rear silencer -1-- 4-. = Insert front silencer -2- and rear silencer “4"into double clamp -3- up to dimensions -a and b- = Align serew-type connection!6f double clamp -3- horizontally and lightly tighten bot. — Align front silencer -2and rear silencer -1- horizontally, and tighten bolts -3- for double clamp. Installation location of rubber mounting = Align rubber mounting -1- in such @ way thet the distance -2- is 8mm, (Fre Check entirs installation location of exhaust system. 12 Checking-exhaust system for leaks Start engine and run at idling speed g. Seal end exhaust pipes with dloths or plugs, for exampl the curation of the leakage test. Check (by listening) points of connection between exhaust manifold and cylinder head, and between turbocharger and front exhaust pipe to make sure there are no leaks. Reectify any leaks that are found. 13 Aligning exhaust system free of stress Special tools and workshop equipment required cose @ common rail) - Edition 04.2013 1. Exhaust pipes. sioncers 375 Amarok 2011 > # Torque wrench (5...50 Nm) - V.A.G 1331- + Exhaust system must be aligned when cold, Procedure ~ Loosen bolts of double clamp -3- Tighten bolts hand tight. Align exhaust system until the marking- 4- is visible. Align bolts of double clamp -3- horizontally. Align rubber mountings -1- for front silencer lencer -1- in such a way that dimension -a- is € mm. Tighten bolts for double clamp -3.. Specified torques # 2°11 Assembly overview- silencers’, page 374 4-cylinder diesel engine (2.0 | engine, common rail) . Edition 04.2013 V.A.G 1331 and rear si- 376 ep. o126-- Exhaust systom Amarok 2011 > A-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 2 Cleansing exhaust emissions ='2.1 Assembly overview - emission control (diesel particulate filter) page 3: ="2.2 Assembly overview - emission control (catalytic convert ery page 379 2 in ulate fi a = "2.4 Removing and installing catalytic converter’, page 387 24 Assembly overview - emission control (diesel particulate filter) 41 - Screw+type clip Always renewratter re- moving Fit screwi-type clip by hand, 2 When installing, first fit sctewetype clip on tur- bbecharger for exhaust pipe. 2 8Nm 2- Gabket Renew after removing Electronic parts cata- logue (ETKA) must not Get into the siots on the probe body. 50Nm| 4-- Control line witK-union nut Q 20Nm 5 - Exhaust gas temperature sender 3 - G495- Grease thread of sender using high-temperature aste > Electronic, arts Catalogue (ET- KA) Connector (brown) at coupling point of air filter a 45Nm 6 - Exhaust gas temperature sender 4 - G648- 2 Grease thread of sender using high-temperature paste = Electronic Parts Catalogue (ETKA) Connector (orange) at coupling point of air fiter 2 45Nm ing exhaust emissions 377 4-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 7 - Bracket with control lines 8-Clip 9 Control pipe 10 - Union nut Q 20Nm 11 - Exhaust gas pressure sensor 1 - G450- Adaptation is necessary after this component has been renewed = Vehicle diagnostic tester. Removing and installing > page 360 12- Bolt a 5Nm 13 - Front exhaust pipe Take into account the fact that there are different types = ETKA (electronic parts catalogue) O Handle carefully to avoid damage. + Transport shock-fres. + Do not kink flexible hose, + Do not stretch flexible hose. Q Removing and installing = page 384 14- Particulate fiter + Assembly sequence must be adhered to during installation to ensure stress-free installation, Position particulate fiter with new gasket = Item 2 (page 377) and new screw-type clip = Item 1 (page 377) . Tighten serew+type clip > Item 1 (page 377; Removing and installing = page 381 15 - Bracket Secured to gearbox on right O Attaching bracket to gearbox" bage 380 16 - Bolt Q 20Nm 17 - Bracket O Fastenedto engine support on right O Metal type a Fasten to bracket on engine support = page 380 18-Bott © O 20Nm 19 - Mounting 5 378 6p. o126- Exhaust systom Amarok 2011 > Accylinde didsél @ngine (2.0 | engine, common rail) - Edition 04.2013 22 Assembly overview - emission control (Catalytic converter) (B) Note ¢ After working on the exhaust system, ensure that the system is not under stress and that there is sufficient clearance to the bodywork. Loosen double clamp and cljo if necessary. Align silencer and exhaust pipe so that sufficient clearance is maintained to the bodywork and the support rings-are evenly loaded. ¢ Renaiv selt-focking nuts, 1- Scremtype clip Always renew after re- moving 2 Fit screw-type clip by hand 2 When installing, frst fasten the screw-type clip for the exhaust pipe on turbocharger 2 8Nm 2- Gasket Renew after fémoving Note installation posi. tion 3 Front exhaust pipe with cat- alytic converter Take into account the fact that there are differ- enttypes = ETKA (elec tronic parts catalogue) Handle carefully to avoid damage. When installing, first fasten the top screw type clip for the exhaust, pipe on turbocharger + Transport shock-free. + Do not kink flexible hose. + Donat stretch flexible hose. Removing and installing = page 387 4- Bolt a 20Nm 5 - Bracket 2 Secured to gearbox on right Attaching bracket to gearbox = page 380 6- Bolt a 20Nm 7 - Bracket 2 Fastened to engine support on right Metal type Attaching bracket to engine support = page 360 ing exhaust emissions 379 @ Amarok 2011 > 4-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 8 - Bolt Q 20Nm 9- Bolt 20Nm Fasten to bracket on gearbox = Secure bracket -2- to gearbox -1- with bolts -3- Fasten bracket to engine support — Secure bracket -2- to engine support -1- with bolts -3.. 380 6p. 07.26 Exhaust systom A-cylindendliedel &iigitié!(20:1engine, common rail) - Edition 04.2013 23 Removing and installing particulate filter Special tools and workshop equipment required . . V.A.G 1331 Torque wrench (6...50 Nm) -VAG 13345 Torque wrefich (40...200 Nm) - V.AG 1332 Hose clip pliers - VAS 636. VAS 6362 Amarok 2011 > V.A.G 1332 eS 2. Cleansing exhaust emissions 381 4-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 Removing ZX warns Risk of burns. Parts of the exhaust system may be hot. Allow exhaust system to coo! before removing. When doing any repair work, especially in the engine compart- ‘ment, pay attention to the following due to the cramped condi- tions. * Route all the various lines (e.g. for fuel, hydraulics, acti- vated charcoal fiter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original po- sitions. @ Toavoid damage to lines, ensure sufficient clearance from all moving or hot components. '* Cut through cable ties carefully and install new ones in the same position. - Detach vacuum hose -2- from upper toothed belt guard -1-. = Open clips -arrows- and remove toothed belt guard -1-. = Remove pipe -arrow- from cylinder head cover. 382 pep. o126- Exhaust sysiom A-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 Detach hoses from intake hose -3- bracket -arrov. Release and pull off wiring hamess connector -2-. Detach wir- ing harness -2- from intake hose -2.. Open clips -1- and -4- and remove intake hose -3- together with pipe -5- Remove air flter = pave 368 . Disconnect connectors -1, 2 and 3- for exhaust gas tempera- ture sender 1 - G235- (black connector), exhaust gas temper- ature sender 3 - G495- (brown connector) and exhaust gas temperature sender 4 - G648- (orange connector) at coupling point (in front of air fier) Loosen cable ties -3-, free lines -1 and 2- from fittings, and lay them to one side. Clamp off coolant hose -2- with hose clamps up to 25 mm = 3094. Open spring-type clip -1- for coolant hose -2- and pull coolant hose off. 2. Cleansing exhaust emissions. 383, 4-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 = Open spring-type clips -1- and pull hoses -2 and 3- off contol lines for particulate filter. — Undo and remove bolt -2- for coolant pipe -1- at wheel housing and tie on coolant hose somewhere at a slightly higher point. (F) noe Do not bend coolant pipe. Undo screw -1- of screwstype clamp -2- between particulate filter and turbocharger and remove clamp -2.. = Undo and remove bolts -3- for particulate filter bracket ~4. — Undo screw -1- of clamp -2- ~ Undo and remove fits -3- for exhaust pipe bracket -4-. 384 pep. o126- Exhaust sysiom eazy @ A-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 - When removing particulate fiter, push -1- the coolant pipe -2-allittle to one side, = Carefully remove particulate filter -1- upwards out of the en- gine compartment, Installing Installation is carried out in the reverse order: note the following: LX cauion Ensure particulate fier is not stressed when installed. The particulate fiter could be damaged. Follow installation sequence. Use new clips and gaskets. + Assembly sequence for installation of particulate filter must be adhered to during installation to ensure stress-free installation 2. Cleansing exhaust emissions. 385, 4-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 4 When installing particulate filter, push -1- the coolant pipe -2- alittle to one side, Install particulate fiter -1- carefully. # Screw ih bolts -3- for particulate filter bracket -4- a few tums # Position particulate fiter with new gasket = Item 2(page 377) and new screw-type clip = Item 14page 377) Fit exhaust pipe bracket -4- and tighten bolts -3- hand-tight . } c Fit clamp -22and tighten screw -1- slightly. - Tighten serew’- for serewstype elip = Item 1 (page 377) -2- Tighten bolts = itémn 18 (page 378) -3-. Tighten bolts = Itern 48 (page 378) -3.. a Tighten screw -1- for clamp2-, bem J OS Reas (Temes eee eee = Fasten lines -1 and 2- with new cable ties 386 6p. 01 26- Exhaust systom A-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 - Connect connectors -1, 2 and 3- for exhaust gas temperature sender { - G235- (black connector), exhaust gas temperature sender 3 - G496- (brown connector) and exhaust gas temper- ature sender 4 - G648- (orange connector) at coupling point (in front of air fiter), and make sure they engage securely. = Install air iter = pace 368 fa Note ‘if new particulate fiter was installed, connect = Vehicle dlag- . nostic tester and carry out ‘Ash mass comparison’ [eae Specified torques 2°2,1 Assembly overview emission cont {uibsetartiou, inte fiter)” page 377 @ 2°71 Assembly overviews air filter”, page 368 24 Removing and installing catalytic con- verter Special tools andworkshop equipment required Torque wrench (6...50 Nm) - V.A.G 1331- V.A.G 1331 ‘¢ Lambda probe open ring spanner set - 3337- a 2. Cleansing exhaust emissions 387 4-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 Removing — Remove pipe -arrow- from cylinder head cover. ~ Detach hoses from intake hose -3- bracket -arrows. Release and pull off wiring harness connector -2-. Detach wir- ing hamess -2- fromintake hose retainer -3 (Open clips -1- and-4- and remove intake hose -3- together with pipe 5. Remove air fter:= page 368 Pull vacuum hose -2- off vacuum unit of exhaust gas recircu- lation cooler and vacuum hose -1- off regulating flap potenti- ometer - G584- = Loosen serew-2- for clamp “4- between exhaust pipe -4- turbocharger on cy A 3 SS Pires sf sal ~ Loosen clamp -&-on exhaust pipe ~1- and pul exhaust pipe NA we 388 Rep o-26-Exraust system cylinder diesel engine (2.0 | engine, Undo and remove bolts -3- holding exhaust pipe -2- on gear- box bracket -1-. Release and detach connector -1- of exhaust gas temperature sender 1 - G235- on front right wheel housing -3- at the cou- pling point -2.. Then, free wring harass from fitings and lay tHtoone side Carefully remove front exhaust pipe upwards out of the engine, compartment. Installing Installation is carried out in the reverse order; note the following: Use néw clips and gaskets. Install front exhaust pipe and first fasten the top screw-type clamp for the exhaust pipe on turbocharger ‘Secure front exhaust pipe with all brackets, and fit screw-type clip = Item 1 (page 374) at bottom. Install air filter > pace 368 Specified torques, . + =22.2 Assembly overview - emission control (catalytic con- Fegan at gremew- emission contol featalitic con: ge common rail) - Edition 04.2013 ing exhaust emissions. 38Q 4-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 3 Exhaust gas recirculation 23.1 Assembly overview - exhaust gas recirculation’, age 300 2'3.2 Assembly overview - exhaust gas recirculation, 132 kW. engine’, page 394 2 Install tion page 392 23.4 Removing and installing exhaust gas recirculation cooler, 132 kW engine’, page 398 =."3.6 Removing and installing exhaust gas recirculation valve N78, 132 kW engine’, page 400 2"3.6 Removing end installing changeover valve for exhaust gee Tecirculation cooler N345 ", page 401 402 3.41 Assembly overview= exhaust gas recirculation 1 - Exhaust gas recirculation valve - N18- with exhaust gas recirculation potentiometer - 6212. 2 - Vacuum unit for exhaust flap 3 - Exhaust gas recirculation cooler Removing and installing > page 362 4-- Connection Coolant hose schematic diagram = page 175 5 - Bolt (E) re For better accessibility sure the correct torque! of the exhaust gas reci cooler on the turbochar hexagon bolts with par 107 188 Ot« can be usd First, ft bolts on turbo- charger side and screw them in hand-tight. Q 8Nm 6 - Gasket Renew after removing 7 - Bolt 20Nm 8 - Lower pipe 9 - Gasket Renew after removing 390 kop. or 26 - Exhaust systom eazy @ A-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 10- Bolt vores s. @ 20Nm 11- Bolt a 8Nm 12 - Upper pipe . 13 - Gasket ‘ Renew after removing 14- Bolt 2 Renew after removing g a 8Nm 5 3.2 Assembly overview - exhaust gas recirculation, 132 kW engine 1 - Exhaust gas recirculation cooler Removing and installing = page 368 2.- Bracket 2 Forexhaust gas recireu- lation cooler. 3- Bolt 2 Renew after removing a 8Nm 4 Gasket 5- Connecting pipe To exhaust gas recircu- lation valve - N18- 6 - Exhaust gas recirculation valve - N18- 1 Removing end instaling 5 page 400 7 - Connecting pipe From exhaust gas recir- culation cooler 8- Bolt a 20Nm 8. Exhaust gas recrcuiation 391 3.3 Amarok 2011 > Special tools and workshop equipment required ’ + Torque wrench (5...50 Nm) -VAG 1331- Torque wrench (49...200 Nm) - V.AG 1332 Torque wrench - V.AG 131. Drip tray for workshop hoist - VAS 6208- Hose clip pliers - VAS 6340- Hose clip pliers - VAS 83: V.A.G 1331 Ss V.A.G 1410 ‘Special tools and workshop equipment required + Hose clamps up to 25 mm - 3084- * . Small hand-held mirror Flexible magnet 4-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 Removing and installing exhaust gas recirculation cooler V.A.G 1332 NAS 6208 392 kop. or 26- Exhaust systom A-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 Removing (8) note ¢ Exhaust gas recirculation cooler is removed upwards. Conta- minated areas must be cleaned thoroughly after installing. © To facilitate removal of the exhaust gas recirculation cooler, remove the air fiter housing and the exhaust pipe. © For better accessibility and to ensure the correct torque for the bolts of the exhaust gas recirculation cooler, hexagon bolts with part number »N 107 188 Of« can be used. @ Some connectors are diffcult to see. A small hand-held mirror (8 required to unscrew and insert the threaded connection. © Note different bolt lengths for pipes. ¢ Renew gaskets and seals. — Detach vacuum hose -2- from upper toothed belt guard -1-. = Open clips -arrows- and remove toothed belt guard -1-. ~ Remove pipe -arrow-,f'om cylinder head cover. Amarok 2011 > 8. Exhaust as recrcuiton 393 Amarok 2011 > 4-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 = Detach hoses from intake hose -3- bracket -arrow Release and pul off wiring harness connector -2-. Detach wir- ing harness -2- from intake hose retainer -3-. Open clips -1- and -4- and remove intake hose -3- together with pipe -5- Remove air fter > page 368 = Pull vacutiin hose off vacuum unit of exhaust gas recirculation Coolee-1-and vacuum hose rom regulating lap potentiometer, - GB84- -2-. ‘ Detach connectors -1- from exhaust gas recirculation valve - N18--2- and regulating flap for potentiometer - G584- -3., Vehicles with particulate filter me a = Undo and remove bolt-2- for coolant pipe -1- at wheel housing and tie on coolant hose somewhere at a slightly higher point. - Remove particulate fitter = page 381 Vehicles with engines compliant with EU 4 and EU 3 standards 394 Rep o:26- Exraust system 0 —— eS ag Amarok 2011 > @ ! 4-oylinder dieséFengine (2.0 engine. common rail) - Edition 04.2013 = Loosen bolt -2- in screwstype clip -1- for front exhatist pipe <4. at turbocharger. : = Unserew and remove bolts -3-in bracket for front exhaust Bip 4 : — Loosen screw-type clip -3- for front exhaust pipe -1-. . ary = Undo and remove bolts -3-for front exhaust pipe -2-at bracket a — Release and detach connector-1- of exhaust gas temperature sender 1 - G235- on front right wheel housing -3- at the cou- pling point -2-. Then, free wiring hamess from fitings and lay itto one side. Carefully remove front exhaust pipe upwards out of the engine ‘compartment. Continuation for all vehicles 8. Exhaust as recrcuiton 395 4-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 ~ Clamp off coolant hose 3094. = Loosen spring-type clip -3- and remove coolant hose -2- at ‘exhaust gas recirculation cooler -1.. with hose clamps up to 25 mm = — Undo and remove bolts -2- for pipe -1- and remove pipe from ‘exhaust gas recirculation cooler. (F me The bolts -3- for the pipe -4- are not undone. = Clamp off coolant hose -2- with hose clamps up to 25 mm - 3094. = Open spring-type clip -1- for coolant hose ~ hose off. ‘and pull coolant — Undo‘and remove bolts -2- and -3- for pipe -1- and remove pipe, (Byte Bear in mind the differences between the types of bolt! Ne Win 396 kop. o126- Exhaust systom Amarok 2011 > A-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 = Unclip connector -2- on oil pressure switch - F1- — Undo and remove bolts -2- at exhaust gas recirculation cooler on — Undo and remove bolts -2- at exhaust gas recirculation cooler ae = Carefully remove exhaust gas recirculation cooler upwards. = Clean contaminated areas thoroughly. Installing Installation is carried outit the reverse Srtfer:incte the following: Renew gaskets and seals. (Fi) v0 For better accessibility and to ensure the correct torque for the bolts -2- of the exhaust gas recirculation cooler on the turbo- gharge side, hexagon bots with part number N 107 188 01 can use = Replace both bolts -2- at exhaust gas recirculation cooler on Tight with hexagon bolts (part number »N 107 188 O1«), and tighten hexagon bolts. (F) re & Note different bott lengths for pipes, ¢ Only screw pipe bolts in loosely at first, then tighten. a 8. Exhaust as recrcuiton 37 4-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 = Replace screw-type clamp -1- for front exhaust pipe -4-. — Replenish coolant > page 182 Specified torques # 23.1 Assembly overview - exhaust gas recirculation page 390 # > °2.1 Assembly overview - emission control (diesel particu inte filler’, page 377 * fateh pees ° eden page 7s oven emission contol estate con: SG ieren) page es 3.4. Removing and installing exhaust gas re- circulation cooler, 132 kW engine ‘Special tools and workshop equipment required ix 4 Hose clamps up to 25 mm - 3094. = + Drip tray for werkhop ho -VAS 6208. 4 Hose clip pliers - VAS 6362- 398 Rep o:26-Exraust system eazy @ A-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 [F) Note The exhaust gas recirculation cooler is removed upwards. Contaminated areas must be cleaned thoroughly after instal Jing. ¢ Renew gaskets and seals. Removing = Clamp off coolant hose -2. leading to input to exhaust gas re- circulation cooler -1- with hose clams up to 25 mm - 3094- — Loosen clamp -3- and pull coolant hose -2- off exhaust gas recirculation cooler -1-. = Clamp off coolant hose -1- coming from output of exhaust gas recirculation cooler -3- with hose clams up to 25 mm - 3094- = Loosen clamp -2- and pull coolant hose -1- off output of ex- hhaust gas recirculation cooler -3-. % Undo and remove bolts -1 and 4- and remove connecting pipe. a = Unscrew bolts -3- 8. Exhaust as recrcuiaion 399 Amarok 2011 > 4-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 ~ Unscrew bolts -arrows- and remove bracket -1- of exhaustgas> recirculation cooler. os" = Carefully remove exhaust gas recirculation edéler upwards Installing 4 Installation is carried outin the reverselérder; note the fellowing: (@) note 7 First, screw in all pipe bolts loosely and then tighten them to specified torque. Specified torques 5 @ 23.2 Assembly overview - exhaust gas recirculation, 132 KW ‘engine’, page 391 3 35 Removing and installing exhaust gas re- circulation valve - N18-, 132 KW engine Removing * = Loosen clip -2-and pull pressure Hose off throttle valve control module - J338- — Remove bolt -1- for dipstick guide tubé, = Detach connector -3- from throttle valve céntrol module ~ J338- Undo and remove bolts -2 and 3- and remove pressure pipe a. 400 Rep. o:26- Exraust system eazy @ A-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 =~ Release oil dipstick again. To this, force expanding clip -2- off, using removal lever - 80 - 200- . = Remove throttle valve module - J338- > page 357 — Undo and remove bolts -1 and 3- from connecting pipe -2-. — Remove connecting pipe -2.. = Undo and remove bolts -arrows- and remove exhaust gas re- ulation vaive - N18- -1- from intake manifold: Installing Installation is carried out in the reverse order; note the following! Specified torques @ 23.2 Assembly overview exhadst gas recirculation, 132 KW engine’, page 391 oo 1y overview P 3.6 Removing and installing changeover 3 valve for exhaust gas recirculation cool- ; er-N345- Special tools and workshop equipment required 8. Exhaust gas recrcuiation 401 4-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 # Torque wrench - V.AG 1410- # Socket set 1/4", 22-piece - VAS §526- Removing, = Pull connector -3- and vacuum lines and oull off changeover valve for exhaust gas recirculation cooler - N345- -1-. 7 Unetp locking lug for changeover valve for exhaust gas recir- culation cooler - N345- -1- and remove changeover valve for ‘exhaust gas recirculation cooler - N345- Installing Installation is carried out in the reverse order; note the following: A Caution Do not kink, twist or crush the vacuum lines when routing. This may cause breakdowns. ‘Connect all hoses to stop or at least 10 mm on the relevant ‘connection piece. ‘cooler for leaks + Exhaust gas rédireulation cooler is. 3.7 Checking exhaust i oe ved pele 308 VAG 1410 eg VAS 5528 402 Rep o:26- Exraust system cose @ A-cylinder diesel engine (2.0 | engine, common rail) - Edition 04.2013 = The cooler connection which wil be immersed in the water must be sealed watertight. Using a clamp, secure a hose to the cooler connection at which compressed air is supplied ‘The exhaust gas recirculation coolers ow ready to be immersed in the water. (F re © Supply compressed air at conection where coolant is sup- plied. ¢ The cooler should remain immersed in the water for at least 30 minutes in order to obtain a significant result. ¢ Using a commercially available immersion heater, heat water fo approx. 60-80 °C. © Perform the pressure test with the cooler in vertical position. ¢ The pressure must not exceed 3 bar. Immerse cooler in water as shown in illustration, Hose -arrow- must protrude from water in order to perform pressure test. 8. Exhaust as recrcuiton 403

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