Emissions Recall Service Bulletin/Repair Instructions

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).

1 2 345 6

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