Bypass Flap with Cooler Assembly Overview
Bypass Flap with Cooler Assembly Overview
• Hose connections are secured with either spring type or clamp type clips.
• Always replace clamps.
• The spring type clip pliers (VAS 5024 A) are recommended for installing spring type clips.
• Exhaust Gas Recirculation (EGR) assembly overview. Refer to --> [ Exhaust Gas Recirculation Assembly Overview ] Exhaust Gas Recirculation Assembly Overview.
1 8 Nm
2 Vacuum tube
3 Vacuum line
• For cylinder bank 2.
• Ensure seated tightly.
• To EGR cooler switch over valve 2 (N381)
• Connection diagram for vacuum hoses, refer to --> [ Vacuum Hose Connection Diagram ] [1][2]Diagrams.
4 Vacuum hose
• For cylinder bank 1.
• Ensure seated tightly.
• To EGR cooler switch over valve (N345)
• Connection diagram for vacuum hoses, refer to --> [ Vacuum Hose Connection Diagram ] [1][2]Diagrams.
5 Coolant hose
• Between cooler for EGR and bypass flap.
• Ensure seated tightly.
6 40 Nm
7 Coolant hose
• Ensure seated tightly.
• Use pliers for spring type clamps (VAS 5024 A) to remove and install.
8 5 Nm
9 Coolant line
10 Bracket
• For coolant pipe --> [ (Item 9) Coolant line ].
11 20 Nm
12 Coolant hose
• Ensure seated tightly.
• Use pliers for spring type clamps (VAS 5024 A) to remove and install.
• To heat exchanger for heater unit.
13 Vacuum actuator
• For cylinder bank 1.
• Check operation with hand vacuum pump (VAG 1390) at vacuum connection.
14 Connecting pipe
• For cylinder bank 1.
• From EGR vacuum regulator solenoid valve (N18) (electro-pneumatic) with EGR potentiometer (G212) --> [ (Item 16) with ] Exhaust Gas Recirculation Assembly Overview.
15 Connecting pipe
• For cylinder bank 1.
• To connecting pipe of exhaust manifold --> [ (Item 11) Connecting pipe ] Exhaust Gas Recirculation Assembly Overview.
16 Connecting pipe
• For cylinder bank 2.
• From EGR valve 2 (N213) (electro-pneumatic) with EGR position sensor (G466) --> [ (Item 16) with ] Exhaust Gas Recirculation Assembly Overview.
17 Connecting pipe
• For cylinder bank 2.
• To connecting pipe of exhaust manifold --> [ (Item 11) Connecting pipe ] Exhaust Gas Recirculation Assembly Overview.
18 Gasket
• Replace.
• Note installation position.
19 Bracket
• For bypass flap --> [ (Item 20) Bypass -flap ].
• Fastened to cylinder block.
20 Bypass -flap
• Remove and install with the EGR cooler (--> [ (Item 25) Cooler for EGR ]), refer to --> [ Bypass Flap with Exhaust Gas Recirculation Cooler ] Bypass Flap with Exhaust Gas Recirculation Cooler.
21 Vacuum actuator
• For cylinder bank 2.
• Check operation with hand vacuum pump (VAG 1390) at vacuum connection.
22 Ball pin, 3 Nm
• Fastened to flange of generator.
23 Rubber bushing
24 Bracket
• For cooler for EGR --> [ (Item 25) Cooler for EGR ].
25 Cooler for EGR
• Remove and install together with bypass flap (--> [ (Item 20) Bypass -flap ]).
26 Coolant hose
• Ensure seated tightly.
• Use pliers for spring type clamps (VAS 5024 A) to remove and install.
• From coolant pipe.