Help with expanding the AGR (Gasoline Return) system on a 1.6 TDI Golf VI

Hello Diesel Repairman

On my 1.6 TDI Golf VI, I want to replace the AGR module. All the screws are loosened, but the AGR module can only be moved back and forth by about 1 cm, but it won't come out. I'm frustrated.
My question: What additional components need to be disconnected or loosened in order to remove the EGR module?

I have already removed the exhaust pipe between the EGR module and the engine to the intake manifold. That's it.

Great, anyone who can help me.
Diesler

What is your MKB? Then I'd be happy to take a look at what still needs to be resolved, etc.

Hello Basti1605,

I'm very pleased with your offer. In the meantime, I have removed and reinstalled the AGR module. To do this, I also had to remove the second exhaust pipe, after which there was enough space to remove the AGR.

My engine code: CAYC

In my guide, "Golf VI Diesel, Bucheli Verlag, Volume 1318," it says: "Remove the oil feed and return lines with the exhaust turbine support." I hadn't done this. Perhaps that would have been enough. I have a question for you: Is the exhaust turbine support the approximately 2 cm thick aluminum pipe that runs from below, near the AGR, to the turbine?

Best regards and thanks again for your offer. Diesler

That's exactly the pipe! According to the guide, the DPF should even be removed.
But if it works out now, all the better.

Best regards, Basti

Expansion of the AGR module for Golf 6 1.6 TDI CAYC – personal experience

There are clearly different instructions for expanding the AGR module.
1.) The suggestion to remove the DPF is very complex. This involves loosening the CV joint and moving the engine block – at least according to my "Golf 6 Diesel" manual, Vol. 1318.
2.) According to the instructions in my "Golf 6 Diesel" manual, op. p. 121, the oil feed and oil return lines, along with the exhaust gas turbocharger support, are to be removed.
3.) According to my own experience, removing both exhaust gas recirculation pipes is sufficient.
In all three variations Afterwards, there is enough space to remove the AGR module. The further details, especially a nice diagram of the AGR module, can be found in the above instructions on page 121. You don't need to decide in advance which variant you want to follow. The main problem is loosening the Torx 30 screw on the upper right side of the DPF of the AGR module. To do this, I made a custom, right-angled tool and previously measured it on the new AGR module.

If that doesn't work, you'll have to resort to the more complicated method. I'm glad if this helps someone else.

A picture of the homemade tool would be very nice.

Hallo TDI-GTI-4-Motion,
attached are two photos.
Greetings
Diesler