EGR Temperature Sensor -G98-

Special tools and workshop equipment required

Hose Clamps up to 25 mm Dia. 3094
Torque Wrench (5-50 Nm) V.A.G 1331
Drip Tray for VAS 6100 VAS 6208
Hose Clip Pliers VAS 6362
14 mm Socket T10401

Requirements:

The ignition is turned off.
Engine must be cold.

Removing

-- Remove the noise insulation. Refer to Description and Operation .

-- Drain the coolant. Refer to DRAINING AND FILLING .

NOTE:

The coolant hoses indicated must be removed and moved to the side to perform the repair work on the EGR temperature sensor.

-- Disconnect the coolant hoses from both connections -arrow A- and -arrow D-.

Fig 1: Identifying Removing Coolant Hoses

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Lay aside both coolant hoses -arrow B- and -arrow C- as illustrated.

-- Remove the engine cover. Refer to ENGINE COVER .

CAUTION:

Electronic components could be destroyed when the battery is disconnected:

Follow the required steps when disconnecting the battery.

-- With the ignition turned off, disconnect the ground wire -arrow- from the battery.

Fig 2: Identifying Battery And Ground Cable

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the air filter housing. Refer to AIR FILTER HOUSING OVERVIEW .

-- Remove the battery, the battery tray bolts -arrows- and tray.

Fig 3: Identifying Battery Holder Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector from the EGR temperature sensor -arrow A- and guide the wire out.

Fig 4: Identifying EGR Temperature Sensor

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Note the installed location of the lines and heat shield.

The illustration shows the EGR temperature sensor as seen from the engine compartment looking out from the transmission side -arrow- below the brake master cylinder.

Fig 5: Identifying EGR Temperature Sensor (View From Transmission Side)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Carefully guide the 14 mm socket T10401 with an extension onto the EGR temperature sensor.

Fig 6: Identifying Installation/Removal Of EGR Temperature Sensor Using T10401

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Make sure the wire from the EGR temperature sensor is guided into the groove on the 14 mm socket T10401 -arrow A-.

Fig 7: Identifying Installation/Removal Of EGR Temperature Sensor Using T10401

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the EGR temperature sensor and remove it.

Installing

-- Install in reverse order of removal. When doing this note the following:

NOTE:

EGR temperature sensor tightening specification: 20 Nm

Cut out the gasket and replace if it is damaged or leaks.

Maintain the tightening specification.

CAUTION:

Secure the heat shield mats in their original installed position.

Make sure the entire connection is seated securely.

Replace the self-locking nuts, the seals, the gaskets and clamps.

Hoses are secured with spring-type clips.

Hose clip pliers VAS 6362 or VAS 6340 are recommended for installing spring clamps.