Volkswagen Workshop Service and Repair Manuals

Removing particulate filter with NOx storage catalytic converter   WARNING When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions: t  Route all the various lines (e.g. for fuel, hydraulics, activated charcoal filter system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original positions. t  Ensure that there is sufficient clearance to all moving or hot components. –  Remove engine cover panel → Chapter. –  Remove intake hose → Item between air mass meter -G70- and intake connecting pipe. Loosen spring-type clips using spring-type clip pliers -VAS 6362-.

–  Disconnect »orange« connector for exhaust temperature sender 2 -G448--1- and »black« connector for Lambda probe -G39--3- on plenum chamber bulkhead.

–  Disconnect »brown« connector for exhaust temperature sender 3 -G495--1- (secured behind bracket). –  Guide wiring/lines out of retainers -2- on plenum chamber bulkhead and on turbocharger.

–  Pull connector -2- off differential pressure sender -G505--1-. –  Unscrew securing bolt -4- and remove retainer -3- with differential pressure sender -G505--1- in direction of -arrow- and move aside (control wiring remains connected). –  Unbutton heat shield and pull connector off exhaust gas pressure sensor 1 -G450- → Chapter. –  Pull off the control line of pressure sensor 1 for exhaust gas -G450-. Loosen the spring-type clip with the special pliers for spring-type clips -VAS 6362-. –  Unscrew securing bolt and remove retainer with exhaust gas pressure sensor 1 -G450- and move aside (control line to particulate filter remains connected). –  Remove noise insulation → General body repairs, exterior; Rep. gr.66.

–  Remove heat shield for right drive shaft -arrows-. –  Remove lower bracket for particulate filter → Chapter.   Note Unscrew securing nuts above bracket with ratchet ring spanner -T10384-. –  Remove exhaust gas recirculation filter → Item. –  Remove particulate filter from upper bracket and loosen bracket on cylinder head → Chapter. –  Remove securing clamp between particulate filter and turbocharger → Chapter.

–  Unscrew nuts -arrows- and pull underbody cover down slightly.   Note Note routing of cables/lines → Chapter.

–  Disconnect »orange« connector for exhaust temperature sender 4 -G648--1- and »brown« connector for Lambda probe after catalytic converter -G130--3-. –  Pull connector off retainer -2- and guide wiring/lines out from underbody -arrows-. –  Unscrew hanger for NOx storage catalytic converter on subframe → Chapter. –  Lower subframe approx. 6 cm → Running gear, axles, steering; Rep. gr.40. –  Remove tunnel bridge → Chapter. –  Remove securing clamp between NOx storage catalytic converter and exhaust flap control unit -J883-.   Caution Danger of damaging decoupling element between particulate filter and NOx storage catalytic converter. When removing and installing: t  Do not bend decoupling element more than 10°. t  Install decoupling element so that it is not under tension. t  Take care not to damage wire mesh on decoupling element. t  The decoupling element must be secured with transportation lock -T10404- to stop overstretching. –  Remove securing clamp between NOx storage catalytic converter and particulate filter and remove NOx storage catalytic converter. –  Remove particulate filter. Note electrical wiring and components when doing this.