NHTSA ID Number: 10133439
Manufacturer Communication Number: Emissions Recall
TSB/Document Date: 2018-04-16
Summary
Updated work procedure, 2010 Model Year pre-repair aftertreatment system inspection.
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,
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TSB/Document ID: Emissions Recall
Replacement Service Bulletin Number:
MFR Communication Date: 2017-11-10
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING:EXHAUST SYSTEM
MFR Component System:
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