How do you get to the secondary exhaust gas bypass valve in 2002 Beetle for replacement?

How It Works

Get an answer in three easy steps. Here's how it works...

Ask Your Question

1. Ask Your Question

Enter your VW question at the top of this page and click Get An Answer.

Pick Your Priority

2. Pick Your Priority

Tell us how quickly you want your VW question answered.

Get An Answer

3. Get An Answer

Connect with your VW mechanic via online chat or telephone call.

Get An Answer 

Answer

Customer

How do you get to the secondary exhaust gas bypass valve in 2002 Beetle for replacement?

Last updated
Relly De Jesus
VW Mechanic

Hello and welcome to ExpertHelp.com! My name is Relly De Jesus and I'm going to do everything in my power to answer your question to your full satisfaction!

Before we get started, I want to remind you ExpertHelp.com is an independent professional support company. We do not have any affiliation with VW nor are we paid to provide support on their behalf. However, we have helped hundreds of customers with similar questions and believe we can help you too. OK, let’s get started! :)

I’m available to chat now. Please let me know that you are ready by posting a response. I’ll leave my chat session open for the next 15 minutes or so and wait for your reply. If I don’t catch you this time, please respond with a few times (including your timezone) that work best for you and we can connect then.

Last updated
Relly De Jesus
VW Mechanic

Hello James

How are you doing? May I ask if you are referring to the EGR valve? I'll be standing by for your response.

Image result for 2002 vw beetle egr valve

Thank you

Relly

Posted
Customer

All of the sources I have looked at call it "exhaust gas bypass valve"  It is mounted on the exhaust manifold heat shield. Its purpose is to keep fresh intake air from entering the exhaust system until the engine is up to tempature then it opens and adds oxygen to help the catalytic converter operate at best efficienance. The engine in this car is a 2.0 liter 4 cylinder. I learned a lot from u-tube, but not how to remove it. It may have to be taken of with two bolts from under the car(I don't have a lift).  I hope I have sent an image of the valve I have purchased and it is like the one I can see on the car.  Jamesphoto of valve mounted on exhaust manifold heat shield.

Posted
Customer

The valve was purchased under the brand name Intermotor P/n DV146.  The manufactures name on the valve itself is Pierburgm 7.22778.80.0.  Hope this helps.

Posted
Relly De Jesus
VW Mechanic

Hello James

Good to hear back from you. Yes this is called an EGR valve as well. It just have a different look and people called it by different names. But it's an Exhaust Gas Recirculation. This beetle has a TDI engine?

Relly

Posted
Customer

No is is gas 2.0 l.

Posted
Relly De Jesus
VW Mechanic

Ok, it's almost like this right? 

Image result for 2002 vw beetle egr in exhaust manifold

Posted
Customer

YES, The photo you show is looking at the under side of the exhaust manifold heat baffle. The valve is on the top side. I have the top of the engine cleaned off and you can tell the two bolts that hold it on are coming from under neath the shield and I can not reach them from top side.

Posted
Relly De Jesus
VW Mechanic

Great... I'm checking on some files that can help you with the removal James. Looks like that it's the same with MK IVs and Golfs. Just give me a bit. Thank you

Posted
Customer

Here is a photo of the valve I have.  img_0001.jpg

Posted
Relly De Jesus
VW Mechanic

Hello James... you removed the bolts encircled red? 

Posted
Customer

Do those go into the exhaust manifold? or engine?  They must be accessable from the top side,right?

Posted
Relly De Jesus
VW Mechanic

Yes James. The heatshield can be accessible from the top. They need to be removed to replace the valve. Have you tried removing the heatshield?

Posted
Customer

No, I guess I was worried that the bolts that hold the heat shield on might brake off in th block or manifold then I would really be up a creek.  I thought if the two bolts that hold the valve to the heat shield if the broke or stripped the threads the the valve would be better. So I guess I was hopeing I could get to them from the under side.  Not possible?

Posted
Relly De Jesus
VW Mechanic

Yeah... It's not possible to access it underneath the heatshield while it's attached to the headers. Sorry it took me long to get to this decision. I was thinking there's something else you want to remove that I don't know about. I strongly suggest that you spray PB buster or WD40 before removing the bolts of the heatshield. It's best that you soak those bolts first just to be safe. Once you removed the heat shield you're good in replacing the valve. It's best that you perform the removal while the engine is cold. Is there anything else I can add or help you with James?

Posted
Customer

No I think you for your help!  James

Posted
Relly De Jesus
VW Mechanic

Dear James, It was a pleasure helping you with your VW issue today. Here is a summary of the resolution.

Issue identified : EGR or bypass valve replacement
Solution Implemented : Adviced cx to remove the heatshield to gain access to the bolts of the valve. Solution Accepted
If issue resurfaces : Advised to contact us at s**t@experthelp.com or call us on our support number ***-***-**** )

Posted
Customer

Just a note about the bypass valve and heat shield removal.  I have some update info on the removal yesterday.  there are 6 bolts that hold the heat shield on.  I the photo you circled two in red, but the two circled in white also need to be removed plus there are two more right next to the valve itself.  I have included two photos, one that was taken with the unit still in on the engine and the other of the heat shield after removal.  Also the steel tube fitting going to the valve had to be disconnected and the Oxygen sensor that goes the hole in the center of the heat shield had to be removed. Then after all that the unit can be removed up thru the top. It is difficult to see all these holes in the photos but they are there

Posted
Relly De Jesus
VW Mechanic

Hello James... Thanks for the pictures. It can be useful to those who will see our conversation. You have a great day!

Posted
Get An Answer 

quoteTestimonialsquote

About ExpertHelp

ExpertHelp is changing the way you connect with service professionals.

Whether you have a quick question while preparing your taxes, troubleshooting a computer problem, or need to hire an attorney, ExpertHelp is the most convenient and affordable way to connect with the right service professional to get the job done.

ExpertHelp has been in business since 2011, is an A+ Rated Better Business Bureau accredited member, and offers a 100% satisfaction guarantee on every question you ask!

Get An Answer 

More VW Questions...

Date
Questions

9/15/2018
My 76 super beetle hesitates in 3rd & 4th gear. At the top of the...

6/4/2018
How do you open your bonnet on a 2011 UK B7 Passat when the initial...

4/29/2018
my 1999 vw eurovan with 12 valve vr6 is having poor idle issues....

4/7/2018
How do you get to the secondary exhaust gas bypass valve in 2002...

4/6/2018
van will not start.i just changed tranny oil and filter.maby over...

Ask Your VW Question & Get An Answer Now!