EGR Valve replacement instructions and diagrams needed?

Tiny
ALESSANDRO ALBERTIN
  • MEMBER
  • 2011 VOLKSWAGEN PASSAT
  • 2.0L
  • 4 CYL
  • 2WD
  • MANUAL
  • 160,000 MILES
Hello,

I would like to change the AGR Kühler (EGR Valve) on my car, could you send me a step by step diagram as always, how should I do it?
A thousand thanks,
Alessandro Albertin
Wednesday, October 25th, 2023 AT 10:45 AM

1 Reply

Tiny
BORIS K
  • MECHANIC
  • 762 POSTS
Hello,

The EGR cooler (AGR KÃ hler) and the EGR valve are combined in 1 component. See image 1below.

It takes about 6 hours to replace the component.

The component is located at the rear of the engine, underneath the turbo.
Easiest accessed from underneath.
Suggest loosening the right drive shaft from transmission flange to give better access.
The driveshaft is attached to the transmission flange with 6 10mm spline bolts.

Start on top of the engine.
Remove the intake air pipe to the turbo to gain access to the EGR pipe.
Loosen the 2 bolts holding the pipe to the EGR cooler.
Loose the clamp holding the DPF to the turbo exhaust housing.
Loosen the securing bracket for the DPF and securing bolt on the other side so that it can be moved out of the way. See image 2 showing the lower bracket, held on with 2 nuts.
Before moving DPF ensure to loosen the wiring behind the oxygen sensor.
Under the vehicle remove the right front wheel and inner fender liner.
Loosen the DPF lower bracket.
You can also access the coolant pipe to the EGR cooler, near DPF.
Remove pipe, ensure that you catch any coolant spill.
Remove the 2nd coolant pipe on the other side of the EGR cooler.
See image 3.
Remove banjo bolts for turbocharger oil return and feed pipes.
See image 4.
Loose and remove the right gas pipe from EGR cooler and exhaust manifold.
The left gas pipe is easiest accessed from the top by removing the intake air pipe.
See image 5+6.
Remove the oil return pipe for the turbo.
The oil feed pipe (thinner pipe) is best left attached to the turbocharger.
Loosen the 4 T30 torx bolts holding the EGR cooler and remove the component.

A good video:
https://youtu.be/FjJ5GMo6kYM?si=G_HT-uZRt0QQ1hqR
and
https://youtu.be/ORbUbh-IEzI?si=TkM1oB20Iw1hfms8

Hope this helps.

Cheers, Boris
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Thursday, October 26th, 2023 AT 3:31 AM

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