Volkswagen Workshop Service and Repair Manuals

Removing and installing particulate filter with front exhaust pipe (Polo) Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331-

t  Lambda probe open ring spanner set -3337-

t  Transport guard -T10403-

t  Tensioning strap -T00038-

t  Engine and gearbox jack -VAG 1383A-

t  Tool set -T10395- »Carry out the following work sequence« –  Turn wheels to straight-ahead position. –  Loosen universal joint → Running gear, axles, steering; Rep. gr.48.

–  To do this, remove cover -2- and unscrew plastic nuts -1-.

–  Unscrew bolt -1- from universal joint and pull universal joint off in direction of arrow. –  Remove engine cover panel → Chapter. t  -1- Separate exhaust gas temperature sender 1 -G 235- connector t  -2- Separate exhaust gas temperature sender 3 -G 495- connector t  -3- Separate exhaust gas temperature sender 4 -G 648- connector

t  -4- Separate Lambda probe -G 39- connector

–  Separate connector to pressure differential sender -G 505--2-. –  Unscrew pressure differential sender -G 505- → Item. –  Pull lines out of retainers on engine and remove heat shield from particulate filter; if necessary remove cable ties. –  Unscrew Lambda probe -G 39- using Lambda probe open ring spanner set -3337- → Item. –  Unscrew exhaust temperature sender 3-G 495- using spanner -T10395/6- → Item.

–  Remove securing clamp -1- between particulate filter and turbocharger.

–  Remove bolt -1-. –  Remove noise insulation → General body repairs, exterior; Rep. gr.50.

–  Open bracket -B- of hydraulic lines -A-.

–  Remove pendulum support -arrows-. Item -1- must not be loosened. –  Place engine and gearbox jack engine and gearbox jack -VAG 1383A- below subframe. –  Undo bolts from subframe and replace them with locating pins. → Running gear, axles, steering; Rep. gr.40 –  Loosen anti-roll bar at top of coupling rod → Running gear, axles, steering; Rep. gr.40. –  Lower subframe with engine and gearbox jack -VAG 1383A-; steering remains on subframe. The hydraulic steering circuit does not need to be opened for this → Running gear, axles, steering; Rep. gr.40. –  Lower on the right side max. 10 cm -movement arrow-.

–  To prevent the hydraulic lines being overstretched, lower on the left side max. 7 cm. -movement arrow-.   Note Secure subframe with steering box to underbody of vehicle using tensioning strap -T00038-, so that the hydraulic lines are not stressed.

–  Remove securing bolts -1- and remove cover from cylinder block for right drive shaft. –  Disregard -item 2-.

–  Unscrew exhaust gas temperature sender 4 -G 648--item 1- from exhaust pipe downstream of particulate filter.

–  Unscrew bolts -1- and then nuts -2-. –  Remove particulate filter bracket.   Note The decoupling element in the front exhaust pipe must not be bent more than 10° - otherwise it can be damaged.

If the particulate filter is to be re-installed, a transportation lock -T10403--arrow- must always be secured to the decoupling element in front exhaust pipe.

–  Loosen securing bolts -arrows- of clamping sleeve, then push down backwards from front exhaust pipe. –  Detach front exhaust pipe from mounting brackets. Carefully remove front exhaust pipe with particulate filter together with pressure differential sender -G 505- above lowered subframe.

–  Remove particulate filter by turning 180° around its own axis. Installing Specified torques → Chapter. Specified torques for subframe → Running gear, axles, steering; Rep. gr.40.   Note t  Before installing subframe with steering box ensure that seal on steering box contacts the assembly plate without kinks. Ensure opening to footwell is correctly sealed. Otherwise water could leak in and/or there will be more noise. t  Renew seals, self-locking nuts and clip for particulate filter. t  Reinstall all cable ties in the same locations when installing.

Check fitting position of seal -arrow- (steering donut). Installation is carried out in the reverse order. When installing, note the following:

Observe sequence when installing particulate filter:

1.	position particulate filter on turbocharger and secure clip -1- loosely
2.	screw bolts and nuts -2 … 5- in loosely by hand l  particulate filter and retainer must be able to move
3.	tighten clip -1-
4.	tighten nuts and bolts -2- and -5-
5.	tighten nuts and bolts -3- and -4-

Specified torque for bolts for drive shaft heat shield -1- → Running gear, axles, steering; Rep. gr.40, –  Aligning exhaust system free of stress → Chapter.