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

Removing and installing particulate filter

⇒ 2.2.1 Removing and installing particulate filter (LHD)

⇒ 2.2.2 Removing and installing particulate filter (RHD)

2.2.1 Removing and installing particulate filter (LHD)

Special tools and workshop equipment required

  • Torque wrench - V.A.G 1331-
  • Lambda probe open ring spanner set - 3337-
  • Tensioning strap - T00038-
  • Engine and gearbox jack - VAG 1383A-
  • Tool set - T10395-

Removing

  • Turn wheels to straight-ahead position.
  • Loosen universal joint ⇒ Running gear, axles, steering; Rep. gr. 48; Removing and installing steering column.
  • 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 ⇒ 3 Engine cover panel.
  • Detach following connectors and make lines accessible.
  • -1- exhaust temperature sender 1 - G235- connector
  • -2- exhaust temperature sender 3 - G495- connector
  • -3- exhaust temperature sender 4 - G648- connector
  • -4- connector for Lambda probe - G39-
  • Separate connector to pressure differential sender - G505- -2-.
  • Unscrew bolt -3-.
  • Pull lines out of retainers on engine and remove heat shield from particulate filter; if necessary remove cable ties.
  • Unscrew Lambda probe - G39- using Lambda probe open ring spanner set - 3337- ⇒ Item 6 (page 249).
  • Unscrew exhaust temperature sender 3 -G495- using wrench - T10395/6- ⇒ Item 15 (page 250).
  • Remove securing clamp -1- between particulate filter and turbocharger.
  • Unscrew bolts -2-.
  • Undo bolt -3- and swivel bracket towards the front.
  • Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50.
  • Open bracket -B- of hydraulic lines -A-.
  • Remove pendulum support -arrows-.

Do not loosen item -1-.

  • Place engine and gearbox jack engine and gearbox jack - VAG 1383A- below subframe.
  • Unscrew subframe bolts individually and replace with locking pins. ⇒ Running gear, axles, steering; Rep. gr. 40
  • Loosen anti-roll bar at top of coupling rod ⇒ Running gear, axles, steering; Rep. gr. 40.
  • Carefully 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.
  • Unscrew bolts -1- and remove heat shield for right drive shaft.
  • Unscrew exhaust gas temperature sender 4 - G648- -item 1- from exhaust pipe downstream of particulate filter.
  • Unscrew bolts -1- and then nuts -2-.
  • Remove particulate filter bracket.
  • 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 - G505- above lowered subframe.

  • Remove particulate filter by turning 180° around its own axis.

Installing

Installation is carried out in the reverse order. When installing, note the following:

Tightening sequence

1)Position particulate filter on turbo charger and loosely attach clip -1-
2)Screw bolts and nuts -2…5- in by hand • It must still be possible to move particulate filter and bracket
3)Tighten clamp -1- ⇒ 2 Emission control.
4)Tighten bolts and nuts -2, 3, 5- ⇒ 2 Emission control.
5)Bolts -4- ⇒ 2 Emission control.

Specified torque for bolts for drive shaft heat shield -1- ⇒ Running gear, axles, steering; Rep. gr. 40; Suspension,

2.2.2 Removing and installing particulate filter (RHD)

Special tools and workshop equipment required

  • Torque wrench - V.A.G 1331-
  • Lambda probe open ring spanner set - 3337-
  • Tensioning strap - T00038-
  • Engine and gearbox jack - VAG 1383A-
  • Tool set - T10395-

Removing

  • Turn wheels to straight-ahead position.
  • Loosen universal joint ⇒ Running gear, axles, steering; Rep. gr. 48; Removing and installing steering column.
  • 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 ⇒ 3 Engine cover panel.
  • Disconnect connectors -1- for exhaust temperature sender 1 - G235-.
  • Disconnect connectors -2- for Lambda probe - G39-.
  • Unscrew Lambda probe - G39- -1- using Lambda probe open ring spanner set - 3337-.
  • Remove securing clamp -2- between catalytic converter with non-engine-mounted particulate filter and turbocharger.
  • Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50; Body - front; Assembly overview - sound insulation.
  • Separate connector -2- to pressure differential sender - G505-.
  • Unscrew pressure differential sender - G505- -1-.
  • Separate connector -3- to pressure differential sender - G505-.
  • Pull lines from retainers, remove cable ties if necessary.

Do not bend the flexible joint in the front exhaust pipe by more than 10° because it might otherwise be damaged.

If the catalytic converter with non-engine-mounted particulate filter is to be re-installed, a transportation sleeve -arrow- must always be secured to the flexible joint in front exhaust pipe.

  • Open bracket -B- of hydraulic lines -A-.
  • Remove pendulum support -arrows-.

Do not loosen item -1-.

  • Place engine and gearbox jack engine and gearbox jack - VAG 1383A- below subframe.
  • Unscrew bolts from subframe and renew them by 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.
  • Remove securing bolts -1- and remove cover from cylinder block for right drive shaft.
  • Unscrew exhaust gas temperature sender 3 - G495- using - T10395/6- ⇒ Item 5 (page 252) from front exhaust pipe.
  • Remove right underbody panelling ⇒ General body repairs, exterior; Rep. gr. 66.
  • Remove cover from connector for exhaust temperature sender
    • 4 G648-.
  • Disconnect connector for exhaust temperature sender 4 - G648-.
  • Unscrew bolts -1- and then nuts -2-.
  • Remove particulate filter bracket.

If the particulate filter is to be re-installed, a transportation sleeve -arrow- must always be secured to the flexible joint 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 - G505- above lowered subframe.

  • Remove catalytic converter with non-engine-mounted particulate filter by turning 180° around its own axis.

Installing

Installation is carried out in the reverse order. When installing, note the following:

  • Seal ⇒ Item 2 (page 252). Renew.

Tightening sequence

  • 1) Mounting of catalytic converter with particulate filter installed away from engine (RHD vehicles) -1- on turbocharger, clamp -2- (positioning only)
  • 2. Bracket on cylinder block with nuts -4- + -6- (for positioning only). Bolts -5- + -7- also (for positioning)
  • 3. Tighten clamp -2- to turbocharger 7 Nm
  • 4) Tighten left nut -6- to crankcase 25 Nm
  • 5) Tighten right nut -4- to crankcase 25 Nm
  • 6) Tighten left bolt -7- of bracket to diesel particulate filter 25 Nm
  • 7) Tighten right bolt -5- of bracket to diesel particulate filter 25 Nm

Specified torque for bolts for drive shaft heat shield -1- ⇒ Running gear, axles, steering; Rep. gr. 40; Suspension,

Specified torque for exhaust temperature sender/catalytic converter with non-engine-mounted particulate filter (right-hand drive vehicles) ⇒ 2.1.2 Assembly overview - particulate filter (RHD)