1.2 TDI CR engine (EA189) · Exhaust system · Emission control

Particulate filter – assembly overview and fastening

2.1.1 Assembly overview - particulate filter (LHD)

Note

After working on the exhaust system, ensure that the system is not under stress and that there is sufficient clearance to the bodywork.
If necessary, loosen double and single clamps and align silencers and exhaust pipe so that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded ⇒ 1.2 Separating exhaust pipes from silencers.
If particulate filter or pressure differential sender - G505- is exchanged, pressure differential sender - G505- must be adapted using vehicle diagnostic tester as a matter of priority: Guided Functions; Adapting pressure differential sender - G505-.
Removing and installing exhaust manifold with turbocharger ⇒ 1.1 Assembly overview - turbocharger with attachments.
Do not bend the flexible joint in the front exhaust pipe by more than 10° because it might otherwise be damaged.
Renew seals, gaskets and self-locking nuts.

sender - G505- is very sensitive. Be careful not to knock against it when placing it down somewhere with hoses connected.

Only pull hoses off differ‐

ential pressure sender - G505- if it has to be replaced.

2 3 Nm
3 Control cable
4 Clamps
5 Exhaust gas temperature sender 4 - G648-
- 45 Nm, observe warning ⇒ 2.1.1 Assembly overview - particulate filter (LHD)
- When reinstalling temperature sender, grease only the thread with high-temperature paste
  - G 052 112 A3-.
- To remove and install, use wrench T10395/6.
- Tighten with wrench T10395/6 ⇒ 2.1.1 Assembly overview - particulate filter (LHD)
6 Lambda probe - G39-
- Removing and installing ⇒ 6 Lambda probe
7 Heat shield
8 9 Nm
9 Particulate filter
- Removing and installing ⇒ 2.1.2 Assembly overview - particulate filter (RHD)
10 Seal
- Renew
- Observe installation position
11 Clip
- Renew after removal
- 7 Nm
12 Nuts
- 25 Nm
13 Bolts
- 25 Nm
14 Bracket
- Bolted to engine bracket
15 Exhaust gas temperature sender 3 - G495-
- 45 Nm, observe warning ⇒ 2.1.1 Assembly overview - particulate filter (LHD)
- Lubricate thread of sender using high-temperature paste - G 052 112 A3-
- To remove and install, use T10395/6 - tool set- ⇒ 2.1.1 Assembly overview - particulate filter (LHD)
16 Bracket
17 25 Nm
18 Bracket
- For pressure differential sender - G505-.

Extending the torque wrench - V.A.G 1331- with the spanner from tool set - T10395/6- allows the correct torque of 45 Nm to be achieved.

Tightening exhaust gas temperature sender G495

Lubricate thread of sender using high-temperature paste - G 052 112 A3-.
Screw exhaust temperature sender 1 - G495- in by hand.
Then tighten to specified torque using torque wrench - V.A.G 1331- together with wrench from tool set - T10395/6-. Observe warning text ⇒ 2.1.1 Assembly overview - particulate filter (LHD).

Tightening exhaust gas temperature sender G648

Lubricate thread of sender using high-temperature paste - G 052 112 A3-.
Screw exhaust temperature sender in by hand.
Then tighten to specified torque using torque wrench - V.A.G 1331- together with wrench from tool set - T10395/6-. Observe warning text ⇒ 2.1.1 Assembly overview - particulate filter (LHD).

Note

After working on the exhaust system, ensure that the system is not under stress and that there is sufficient clearance to the bodywork.
If necessary, loosen double and single clamps and align silencers and exhaust pipe so that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded ⇒ 1.2 Separating exhaust pipes from silencers.
If catalytic converter with non-engine mounted particulate filter or pressure differential sender - G505- is exchanged, pressure differential sender - G505- must be adapted using vehicle diagnostic tester : Guided functions; Adapting pressure differential sender - G505-.
Removing and installing exhaust manifold with turbocharger ⇒ 1.1 Assembly overview - turbocharger with attachments.
Do not bend the flexible joint in the front exhaust pipe by more than 10° because it might otherwise be damaged.
Renew seals, gaskets and self-locking nuts.

1 Lambda probe - G39-
- Removing and installing ⇒ 6 Lambda probe
2 Seal
- Renew
- Observe installation position
3 Clip
- Renew after removal
- 7 Nm
4 Exhaust gas temperature sender 4 - G648-
- 45 Nm, observe warning ⇒ 2.1.2 Assembly overview - particulate filter (RHD)
- Lubricate thread of sender using high-temperature paste - G 052 112 A3-
- Tightening ⇒ 2.1.2 Assembly overview - particulate filter (RHD).
5 Exhaust gas temperature sender 3 - G495-
- 45 Nm, observe warning ⇒ 2.1.2 Assembly overview - particulate filter (RHD)
- Lubricate thread of sender using high-temperature paste - G 052 112 A3-
- Tightening ⇒ 2.1.2 Assembly overview - particulate filter (RHD).
6 Pressure differential sender - G505- bracket
7 Clamps
8 Control lines
9 Pressure differential sender - G505-
- Removing and installing ⇒ 5.4.1 Removing and installing pressure differential sender - G 505-
10 4.5 Nm
11 25 Nm
12 25 Nm
13 Bracket
- Bolted to cylinder head
14 Catalytic converter with non-engine-mounted particulate filter
- Removing and installing ⇒ 2.1.2 Assembly overview - particulate filter (RHD)

Extending the torque wrench - V.A.G 1331- with the spanner from tool set - T10395/6- allows the correct torque of 45 Nm to be achieved.

Tightening exhaust gas temperature sender G495

Lubricate thread of sender using high-temperature paste - G 052 112 A3-.
Screw exhaust temperature sender in by hand.
Then tighten to specified torque using torque wrench - V.A.G 1331- together with wrench from tool set - T10395/6-. Observe warning text ⇒ 2.1.2 Assembly overview - particulate filter (RHD).