Emissions Recall Service Bulletin/Repair Instructions

TIP

On the date of repair, print this screen and keep a copy

with the repair order.


Confirm the Campaign/Action is open .

If the status is closed, no further work is required.

Note the Applicable Criteria ID  for use

in determining the correct work to be done and

corresponding parts associated.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These

procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To

determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Volkswagen Group of America, Inc. All Rights Reserved.

November 2017
23U3 Page 8 of 75



Check for other Open campaign actions .

Other Open campaign actions must be completed

prior to releasing the vehicle to the customer.
NOTE

At this time it is required to complete this action in

conjunction with Campaign 24CV. Campaign 23U3

requires the condition of the Heated O2 Sensor -G39- to

be verified BEFORE beginning the flash operations

contained in this action.

CAMPAIGN 24CV MUST BE COMPLETED BEFORE

BEGINNING THE 23U3 CAMPAIGN!

Refer to Campaign 24CV at this time, and complete that

action before continuing.
Proceed to Section B
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These

procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To

determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Volkswagen Group of America, Inc. All Rights Reserved.

November 2017
23U3 Page 9 of 75
Section B – Check for Service Initiation

NOTE

RISK of Non-payment!

Not using the IN-FORM tool to document and validate

the modification will stop the processing of payment for

your dealership even if the modification has been

completed.

Look for the image below to indicate labor operations,

parts,

or

labeling

that

requires

IN-FORM tool image documentation.
NOTE

RISK of Non-payment!

Ensure that the “check mark”  is present prior to

beginning any work.


Ensure the Service Initiation Form has a “check

mark” .

o
If the Service Initiation Form does not

have

a

“check

mark”

,

immediately contact your Service

Consultant to complete the initiation.
o
If “check mark”  is present, initiate

Service Modification Documentation

Form and continue work.
DO NOT proceed with any work unless you can initiate

the Service Modification Documentation Form.

Proceed to Section C
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These

procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To

determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Volkswagen Group of America, Inc. All Rights Reserved.

November 2017
23U3 Page 10 of 75
Section C – Check for Pre-existing conditions, Vehicle Modifications, and MIL light on


Perform a visual inspection of the intake,

exhaust, and emissions systems.

o If the visual inspection of the intake, exhaust,

or emissions equipment reveals damage or

concerns, STOP, create a VTA ticket and

contact the Volkswagen Technicians

Helpline.

o If the visual inspection of the intake, exhaust,

or emissions equipment reveals no damage

or concerns, continue the work procedure.

Check for vehicle modifications from original

equipment.

o If vehicle modifications from original

equipment related to emissions components

are found, STOP, create a VTA ticket and

contact the Volkswagen Technicians

Helpline.

o If vehicle modifications from original

equipment related to emissions components

are not found, continue the work procedure.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These

procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To

determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Volkswagen Group of America, Inc. All Rights Reserved.

November 2017
23U3 Page 11 of 75

Check for illumination of the MIL .

o If MIL is illuminated, STOP, create a VTA

ticket and contact the Volkswagen

Technicians Helpline.

o If MIL is not illuminated, continue the work

procedure.

TIP


VTA cases regarding MIL ON conditions

require a GFF diagnostic log to be uploaded at

the time of first contact.

The purpose for this step is to document

vehicle condition prior to initiation of this

action and does not authorize the repair of

any pre-existing conditions.
NOTE

At this time it is required to complete this action in

conjunction with Campaign 24CV. Campaign 23U3

requires the condition of the Heated O2 Sensor -G39- to

be verified BEFORE beginning the flash operations

contained in this action.

CAMPAIGN 24CV MUST BE COMPLETED BEFORE

BEGINNING THE 23U3 CAMPAIGN!

Refer to Campaign 24CV at this time, and complete that

action before continuing.

For Model Year 2011-2014 Criteria 02 vehicles:

Proceed to Section D

For Model Year 2009 Criteria 01 vehicles:

Proceed to Section E

For Model Year 2010 Criteria 02 vehicles:

Proceed to the next step for Aftertreatment System

inspection
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These

procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To

determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Volkswagen Group of America, Inc. All Rights Reserved.

November 2017
23U3 Page 12 of 75
2010 Model Year Vehicles ONLY:


Raise the vehicle on the hoist and inspect the

aftertreatment system configuration.

If the vehicle is a 2010 Model Year with a

two-piece DPF and NOx Trap system that has a

clamp in location :

o

Proceed to Section D for Criteria 02 –

(MY 2010-2014)
If the vehicle is a 2010 Model Year Vehicle with a

one-piece DPF and NOx Trap system that has a

welded joint as shown in location :

o
STOP, create a VTA ticket and contact

the Volkswagen Technicians Helpline.

DO NOT continue with the repair at this

time.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These

procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To

determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Volkswagen Group of America, Inc. All Rights Reserved.

November 2017
23U3 Page 13 of 75
Section D – Emissions Kit Installation (Criteria 02 – MY 2010-2014 ONLY)

NOTE

At this time, verify that Campaign 24CV has been

completed. Campaign 24CV must be completed before

continuing with this repair procedure.

THE 24CV CAMPAIGN MUST BE COMPLETED

BEFORE BEGINNING THIS CAMPAIGN!

NOTE

Section D addresses vehicles built with a two-piece

Diesel Particulate Filter/Lean NOx trap exhaust

system. This system was introduced starting in Model

Year 2010. For vehicles built with a one-piece

system, the DPF must be replaced as there is no

connection on the original components.

Begin with Section E for vehicles having Criteria 01,

with a one-piece DPF/Lean NOx trap system for

Model Year 2009 vehicles ONLY.

If the vehicle is a 2010 Model Year Vehicle with a

one-piece DPF and NOx Trap system that has a

welded joint, STOP, create a VTA ticket and contact

the Volkswagen Technicians Helpline. DO NOT

continue with the repair at this time.


Open hood.

Raise vehicle on hoist.

Unscrew nuts  and pull underbody

cladding down slightly.

TIP
A wedge could be placed between vehicle body and

cladding to allow more work space.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These

procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To

determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Volkswagen Group of America, Inc. All Rights Reserved.

November 2017
23U3 Page 14 of 75

Disconnect »brown« connector for oxygen

sensor after catalytic converter -G130- .

Remove plug from retainer.

Open fasteners for heat shield and pull connector

 off exhaust door control unit -J883- and

thread wiring out of retainers .

TIP
Take a photo of this area now for help with harness

routing during reinstallation later.

Loosen clamps  and remove NOx

storage catalytic converter together with exhaust

door control unit -J883-.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These

procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To

determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Volkswagen Group of America, Inc. All Rights Reserved.

November 2017
23U3 Page 15 of 75

Screw new oxygen sensor after catalytic

converter -G130-  into new NOx storage

catalytic converter  and tighten to 52 Nm

using socket, 22 mm -T10491-.

Set new exhaust door control unit -J883-

with new seal  on NOx storage catalytic

converter . Note notches .

NOTE
Renew all clamps and seals. The clamps before and

after the exhaust door control unit are narrower than

the clamp connecting the particulate filter to the NOx

storage catalytic converter. Ensure that they are

correctly allocated.


Position clamp 1K0 253 725 B  and tighten to

7 Nm.

Place NOx storage catalytic converter together

with exhaust door control unit -J883- with new

seals in installation position. Note notches at

rear connection.

Position all clamps  so that they will not

collide with underbody.

NOTE
Install clamps on the exhaust pipe before installing

pipe into vehicle. Do not attempt to stretch clamps

around pipe once installed, or clamps may fail to seal

properly.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These

procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To

determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Volkswagen Group of America, Inc. All Rights Reserved.

November 2017
23U3 Page 16 of 75

Set clamp 1K0 253 725 B  in place and

engage and torque to 7 Nm.

Set clamp 1K0 253 725  in place and

engage. Then tighten to 7 Nm.

Install the RED validation strap to the NOx

catalytic converter  to confirm that

the proper part is being returned for core.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These

procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To

determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Volkswagen Group of America, Inc. All Rights Reserved.

November 2017
23U3 Page 17 of 75

Connect »brown« connector for oxygen sensor

after catalytic converter -G130-  and attach to

bracket.

Push connector  onto exhaust door control

unit. Secure lines in retainers .

Wrap new heat insulation mats  around

wiring and close fasteners.

Place wires  in clips .
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These

procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To

determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Volkswagen Group of America, Inc. All Rights Reserved.

November 2017
23U3 Page 18 of 75

Wrap new heat insulation mats  around

wiring and close fasteners.

Press underbody cladding upward and tighten

nuts  to 2 Nm.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These

procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To

determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Volkswagen Group of America, Inc. All Rights Reserved.

November 2017
23U3 Page 19 of 75

Remove bolts .

Pull noise insulation  back, out of front

bumper cover .

Remove nut  from exhaust gas recirculation

filter  from below using 13 mm ratchet box

wrench (e. g. Snap-on OEXRM13).

Wrap tape around the tip of a long screwdriver

(e.g. Snap-on SDD162 No.2).
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These

procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To

determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Volkswagen Group of America, Inc. All Rights Reserved.

November 2017
23U3 Page 20 of 75

Apply screwdriver  on side of nut  and

unscrew nut while simultaneously pressing up on

nut.

Open clamp  and remove it.

Remove bolts  and remove exhaust gas

recirculation filter .

Set new exhaust gas recirculation filter  with

new seals in place, screw in bolts  and

tighten to 9 Nm.

Position clamp  and tighten to 3.5 Nm.
Description

EGR Filter

Seal

Seal

Clamp
Part number

1K0 253 120 B

03G 131 547 H

1K0 253 115 AG

1K0 253 725 F
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These

procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To

determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Volkswagen Group of America, Inc. All Rights Reserved.

November 2017
23U3 Page 21 of 75

Push noise insulation  forward into front

bumper cover .

Screw in bolts  and new bolts  and tighten

as follows:

o
Bolt : 2 Nm
o
Bolt : 6 Nm (renew)
Proceed to Section F
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These

procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To

determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Volkswagen Group of America, Inc. All Rights Reserved.

November 2017
23U3 Page 22 of 75
Section E – Emissions Kit Installation (Criteria 01 – MY 2009 ONLY)

NOTE

At this time, verify that Campaign 24CV has been

completed. Campaign 24CV must be completed before

continuing with this repair procedure.

THE 24CV CAMPAIGN MUST BE COMPLETED

BEFORE BEGINNING THIS CAMPAIGN!

NOTE

Section E addresses 2009 Model Year vehicles built

with a one-piece Diesel Particulate Filter/Lean NOx

trap exhaust system. This system was introduced

starting in Model Year 2009. For vehicles built with a

one-piece system, the DPF must be replaced as there

is no connection on the original components.

Begin with Section D for a 2010-2014 Model Year

two-piece DPF/Lean NOX trap system.

DO NOT install the Criteria 01 two-piece

aftertreatment system onto a 2010 Model Year Vehicle.

If the vehicle is a 2010 Model Year Vehicle with a onepiece DPF and NOx Trap system that has a welded

joint, STOP, create a VTA ticket and contact the

Volkswagen Technicians Helpline. DO NOT continue

with the repair at this time.

WARNING

When doing any repair work, especially in the engine

compartment, pay attention to the following due to the

cramped conditions:


Route lines and electrical wiring so that they

are in their original positions E.g. for fuel,

123 4 5 6

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