November 2017

23V6 Page 10 of 37

Section E – Install Hardware
WARNING
Risk of injury. Refer to “Warning and Safety Precautions”, found in Appendix A at the end of this document.

NOTE
•

If the vehicle is equipped with air suspension, vehicle lift mode must be activated before raising vehicle with
vehicle jack or hoist so that the air suspension automatic control procedures do not create difficulties.

•

Vehicle lift mode is automatically switched off at a speed above 3 mph.
If equipped with air suspension:
•

Switch the ignition on.

•

Switch the electrical parking brake on.

•

Press the LOCK button in the center console for 5
seconds.
o

The Vehicle Lift Mode is displayed in the
Instrument cluster and the indicator lamp
in the LOCK button flashes when vehicle
is ready to lift.

•

Turn off the ignition.

•

Carefully pull the engine cover off the bolts one
after the other in direction of . Do not
pull sharply on the engine cover or pull it to one
side.

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

23V6 Page 11 of 37

•

From the passenger side of the vehicle,
disconnect the glow plug connector from
Cylinder 2 Glow Plug with Combustion Chamber
Pressure Sensor -G678- .

•

Clean the glow plug duct in the cylinder head
(contaminants must not fall into the cylinder).
NOTE

Examples for cleaning:
•

Extract large contaminants with a vacuum
cleaner.

•

Spray a brake cleaner or a suitable cleaner into
the glow plug shaft, let it work and then use
compressed air to remove it.

•

Then clean the glow plug duct with a rag
dampened with oil.

•

Loosen the Cylinder 2 Glow Plug with
Combustion Chamber Pressure Sensor -G678 using Glow Plug Socket – VAS6454.

•

Carefully remove the Cylinder 2 Glow Plug with
Combustion Chamber Pressure Sensor -G678 by hand or with a hose without bending it.

•

Carefully install the new the Cylinder 2 Glow Plug
with Combustion Chamber Pressure Sensor
-G678- by hand or with a hose without
bending it.

Part Number

059 905 061 H

Description

Quantity

Glow Plug with
Combustion Chamber
Pressure Sensor

1

•

Using Glow Plug Socket – VAS6454, tighten to
12 Nm.

•

Reconnect the glow plug connector from
Cylinder 2 Glow Plug with Combustion Chamber
Pressure Sensor -G678- and make sure it is
secure.

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

23V6 Page 12 of 37

•

Reinstall the engine cover by first pushing the
cover with both hands into the rubber grommets
in the rear and then into the rubber grommets in
the front.

Figure

Remove the NOx #2 sensor
from the catalyst pipe.

Figure

Cover the NOx #2 Sensor
with a plastic bag (or
equivalent) and secure it
out of the way with a tie
strap
(or
equivalent)
attached through either one
of two holes in the rear
driveshaft
mid-bearing
bracket .

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

23V6 Page 13 of 37

Figure

Remove
the
Particle
Sensor from the SCR
Catalyst pipe.

Figure

Disconnect the electrical
connection at the Particle
Sensor Module .
Remove the two nuts
securing
the
Particle
Sensor Module to the
bracket.

Figure

Remove
the
Particle
Sensor wiring harness from
the securing clips and tie
straps, and then remove the
sensor,
module,
and
harness from the vehicle as
an assembly. Route the
wiring harness up and over
the exhaust bracket .

•

Loosen the screw and remove the clamp from
the Reducing Agent Injector -N474-.

•

Leave the electrical connector and the Reducing
Agent Injector AdBlue feed line connected at this
This will reduce the possibility of
time.
contaminating the electrical connection with
AdBlue.

•

Secure the Reducing Agent Injector out of the way
with a tie strap (or equivalent).

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

23V6 Page 14 of 37

•

Loosen the two nuts on the Dual Clamp
so the clamp can slide back and forth on the
exhaust pipe.

•

Leave the clamp in the installed position at this
time. This will assist in holding the SCR Catalyst
in place while removing the brackets in the next
step.

•

With the assistance of a second technician,
remove the three nuts from the exhaust studs
securing the SCR Catalyst to the Diesel
Particulate Filter (DPF).

•

Remove the bolts from SCR Catalyst brackets at
locations with assistance from second
technician to support the SCR Catalyst while the
brackets are removed.

•

Slide the Dual Clamp towards the rear of the
vehicle, and with the assistance of a second
technician, remove the SCR Catalyst from the
vehicle.

•

Remove the Dual Clamp from the exhaust
pipe and discard.

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

23V6 Page 15 of 37

NOTE

STOP!
Due to corrosion, one or more of the mounting studs
may break when removing the SCR catalytic
converter from the Diesel Particulate Filter (DPF) flange.
DO NOT use a hammer and punch, heat, torch, air
hammer, or other method to remove the studs from
the DPF flange.
Consequential damage to Exhaust Gas Temperature
Sensors, Diesel Particulate Filter, AdBlue Injector Feed
Line, or any other ancillary components WILL NOT BE
COVERED under this action due to damage from heat,
impact, or vibration.
•

If stud replacement is necessary, IT IS
REQUIRED to use a press tool such as the OTC
5057 clevis pin press (or equivalent), or other
available screw or hydraulic type clevis/stud press
tool to remove all necessary studs from the rear
DPF flange.
o

It is advised if one stud breaks that all
three studs are pressed out and replaced
with the bolts/nuts included in the parts
kit.

o

Lubricate the OTC 5057 clevis/stud press
tool threads and the press pin contact tip
with hot bolt paste or anti-sieze lubricant
before each use.

o

For best results, cut any studs that do not
break off as close to the flange as
possible. Pressing a full length stud
increases the chance of bending the stud,
which may complicate the removal
process.

o

Use a cap from the VAS 6122 Engine
Bung Set (or equivalent) to cover the hole
in the DPF to eliminate the chance of
contaminating of the DPF substrate with
metallic particles when cutting the studs.

OTC 5057 Clevis Pin Press

Scan this QR Code or copy/paste the link below
into your internet browser to see a short video
explaining this procedure:
https://audiexternal.kzoplatform.com:443/swf/player/356

•

Install the replacement bolts and corresponding
nuts into the rear DPF flange.

Part Number

Description

Quantity

N 01024713

Replacement Exhaust Bolt

3

N 91130802

Shouldered Hex Nut

3

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

23V6 Page 16 of 37

NOTE
Coat the threads on the nuts and exhaust studs/bolts
with hot bolt paste prior to installation. Refer to the
Parts Catalog.
•

Install the new exhaust Dual Clamp onto the
exhaust pipe at location and slide the clamp
to the rear of the vehicle, but do not tighten.

•

With the assistance of a second technician, install
the new SCR Catalyst with a new gasket between
the SCR Catalyst and DPF . Fit the SCR
Catalyst onto the DPF flange studs/bolts and
install new nuts and tighten to 23 Nm.

•

Slide the Dual Clamp into the installed position on
the SCR Catalyst, but do not tighten. This will
assist in holding the SCR Catalyst in place while
the exhaust system is properly tensioned.

•

Install the bolts for the SCR Catalyst brackets and tighten by hand.

Part Number

Description

Quantity

7P0 254 400 BX

Exhaust Pipe With
Catalyst And Adapters

1

1K0 253 141 AF

Dual Clamp

1

7L5 253 115 C

Gasket

1

N 911 308 02

Shouldered Hex Nut

3

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

23V6 Page 17 of 37

•

Tighten the Dual Clamp until there is a slight
dragging resistance on both the SCR Catalyst
pipe and the rear resonator/muffler
pipe , but do not tighten so much that
the pipes cannot slide in and out of the Dual
Clamp .

•

Pretension the rear resonator/muffler hanging
straps by pulling the rear resonator/muffler pipe
towards the front of the vehicle and
pulling the SCR Catalyst pipe towards the rear of
the vehicle .

In order to reduce harmonic
vibration,
the
rear
muffler/resonator
straps
require 12 mm of
forward tension, as shown
Pull
in the sub-photo.
forward
on
the
rear
muffler/resonator pipe and
insert the pipe deeper into
the Dual Clamp until this
dimension is achieved.
= Rear Resonator Hanging Straps

•

Once the desired
dimension of =
12 mm is achieved,
tighten the Dual
Clamp nuts to 23
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

23V6 Page 18 of 37

Figure

Front
Muffler/Resonator
hanging strap: = 4 mm
If equipped, loosen the
bolts
at
the
forward
resonator pipe hanging
strap and adjust the
bracket until = 4 mm of
forward tension.
•

Figures