23U3 Page 37 of 75

Renewing hose for control line exhaust pressure
sensor 1 -G450

Remove heat shield .



Open clamp and pull hose which was cut
during removal from control line .



Renew hose and tighten clamp . Push
heat insulation over hose and clamp.

Installing particulate filter:
CAUTION
Danger of damaging flexible joint between particulate
filter and NOx storage catalytic converter. When
removing and installing:


Do not bend flexible joint more than 10°.



Install flexible joint free of tension.



Take care not to damage wire mesh on flexible
joint.



The flexible joint must be secured with
transportation lock -T10404- to prevent
overstretching.



Always hold the particulate filter by the heavy
casing when transporting or handling it.


Loosen nut for bracket on top of
cylinder head a few turns.

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 38 of 75



Secure electrical wiring of both upper exhaust
gas temperature sensors (connector colors
brown and orange), the heated oxygen sensor
and differential pressure sensor -G505- with tape
to the top of the heat shield on the particulate
filter.



Position new clamp 1K0 253 725 over the intake
funnel of the particulate filter. Orient new clamp
(positioned downward) to the same clocking as
the original clamp.



Move particle filter into installation position by
»turning« it into center tunnel. Take care not to
damage electrical wiring or components.



Ensure that the transportation lock -T10404 is properly seated.

NOTE
Unlike the production bracket, the supplied bracket no
longer has threaded studs. It must be screwed to the
particulate filter using the supplied bolts, and the nuts
must be screwed on from below. The ball indentation
on the bracket faces the crankcase.


Hold bracket in place and start new bolts for nuts
in bracket from above.



Start nuts by hand a few full turns.

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 39 of 75

Reinstalling subframe:


If Spindles -3346/2- are being used, reposition
engine and gearbox jack -VAS 6931- under
subframe.



Raise the subframe until it is approximately 5 cm
away from the vehicle chassis and screw in bolt
on the wire harness bracket for steering gear
and tighten to 3 Nm.



Carefully raise subframe to installation position
taking locating pins into consideration.



If installed, remove spindles -3346/2- and screw
in new bolts (M12 x 110 mm) at positions . Tighten to 70 Nm and turn an additional 90°.

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 40 of 75



Remove locating pins one at a time and replace
them with new bolts (M12 x 90 mm) at locations
.



Tighten bolts to 70 Nm, then tighten them an
additional 90°.



Take load off engine and gearbox jack
-VAS 6931-, disconnect the securing strap, and
remove it from work area.



Guide coupling rods on left and right into
anti-roll bar , screw on new hexagon nuts
and tighten to 65 Nm.



Screw in new bolts for pendulum
support , tighten them to 50 Nm and then
tighten and additional 90°.

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 41 of 75



Screw new bolts loosely into exhaust
system bracket on subframe.



Fit U-joint in , screw in new
bolt for U-joint and tighten to 30
Nm.



Position footwell trim and hand-tighten bolts
.

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 42 of 75

Tightening order for particulate filter:
NOTE
Due to restricted space, the nut cannot be
reached with a torque wrench. Use a commercially
available 13 mm combination wrench with a 15° offset
and a total length of 140 mm.
A

Position particulate filter with new seal on
turbocharger and secure clamp loosely.
Screw in bolts loosely by hand.
 Particulate filter and retainer must be
able to move
Tighten clamp
7 Nm
Tighten nuts
23 Nm
Tighten nuts
23 Nm
Tighten nut
23 Nm
Tighten nut
23 Nm

B

C
D
E
F
G

NOTE

RISK of Exhaust Leak!
Tightening sequence must be followed. Clamp is
installed when the exhaust gas recirculation filter is
installed.


Tighten bolts securing exhaust system
bracket to subframe to 23 Nm.



Remove transport and protective packaging from
flexible joint for particulate filter.

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 43 of 75

NOTE
The lengths of the driveshaft/gearbox connecting bolts
differ depending on gearbox:
 Manual gearbox = M10x52 mm (N 909 911 02)
 Dual clutch gearbox (DSG) = M10x23 mm
(N 909 910 02)


Position right drive shaft and screw in new bolts
. Tighten bolts initially to 10 Nm, then
tighten further to 70 Nm using a crisscross
pattern.

Installing exhaust pressure sensor 1 -G450NOTE
For greater clarity, exhaust pressure sensor 1 -G450is shown here from behind (perspective of plenum
chamber bulkhead).


1 - Remove bolt .



2 - Remove and dispose of old pressure sensor
.



3 - Insert new pressure sensor into bracket
.



4 - Screw in bolt and tighten to 10 Nm.



5 - Guide bracket with pressure sensor through
openings in new heat shield .

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 44 of 75

NOTE
Take care to connect the hoses (thin) and
(thick) correctly.


Guide exhaust pressure sensor 1 -G450-
into open ends of hoses as shown and secure
thicker hose with new clamp .



Screw in bolt , tighten to 2 Nm and connect
connecter .



Close fasteners on heat insulation mat
around exhaust pressure sensor 1 -G450-.



Wrap new heat insulation mat around wiring
and close fasteners.

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 45 of 75



Position bracket with differential pressure
sensor -G505- opposite ,
screw in new securing bolt until head makes
contact and tighten to 4 Nm.



Push connector onto differential pressure
sensor -G505- .



Connect »brown« connector for exhaust gas
temperature sensor 3 -G495- and secure
behind bracket.



Thread lines into brackets on plenum
chamber bulkhead and on turbocharger.



Connect »orange« connector for exhaust gas
temperature sensor 2 -G448- and »black«
connector for heated oxygen sensor -G39-
on plenum chamber bulkhead and secure wiring
in retainer.

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 46 of 75

Installing exhaust gas recirculation filter:


Set 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.



Position heat shield for right drive shaft, screw in
bolts and tighten to 25 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 47 of 75

Installing NOx storage catalytic converter with
exhaust door control unit -J883

Screw oxygen sensor after catalytic converter
-G130- into NOx storage catalytic converter
and tighten to 52 Nm.
NOTE

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.


Set new exhaust door control unit -J883-
with new seal on NOx storage catalytic
converter . Note notches .



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.



Set clamp 1K0 253 725 B in place and
engage. Then tighten to 7 Nm.



Set clamp 1K0 253 725 in place and
engage. Then tighten to 7 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 48 of 75



Set front tunnel cross-piece in place, screw
on hexagon nuts and tighten to 20 Nm.



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 .

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 49 of 75

Routing electrical wiring on underbody:


Place electrical wiring from oxygen sensor after
catalytic converter -G130- and exhaust gas
temperature sensor 4 -G648- in clips on
heat shield as shown. Connect connector and
secure in bracket.



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 50 of 75



Wrap new heat insulation mat around wiring
and close fasteners.



Press underbody cladding upward and tighten
nuts to 2 Nm.



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)

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 51 of 75

NOTE
On one-piece DPF with NOx trap system (MY 2009
cars), the NOx trap must be separated from the DPF.


Separate NOx trap from DPF using -VAS6254Chain Pipe Cutter (or equivalent).