Continuous Trap Oxidizer: Service and Repair
Particulate Filter with NOx Reduction Catalytic Converter
Special tools, testers and auxiliary items required
• Locating Pins (T10096)
• Wrench SW13 (T10384)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Engine/Transmission Jack (V.A.G 1383 A)
• Hose Clip Pliers (VAS 6362)
• Transportation Lock (T10404)
• The subframe must be lowered in order to remove and install the particulate filter with NOx reduction catalytic converter. The locating pins (T10096) are needed to secure the subframe.
• Turbocharger with exhaust manifold and attachments overview. Refer to => [ Turbocharger and Exhaust Manifold with Attachments Overview ] Turbocharger and Exhaust Manifold with Attachments Overview.
• Particulate filter with NOx reduction catalyst overview, refer to one of the following:
• Engine code CBEA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
• Engine code CJAA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
• Exhaust door control module (J883) with reduction catalytic converter overview. Refer to => [ and Reduction Catalytic Converter Overview ] Exhaust Door Control Unit (J883) and Reduction Catalytic Converter Overview.
• Hose connections are secured with either spring-type or clamp-type clips.
• Always replace clamp-type clips with spring-type clips.
• Hose clip pliers (VAS 6362) or (VAS 6340) are recommended for installing spring clamps.
Removing
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route all lines and wires in their original locations.
• For example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum lines.
• Ensure sufficient clearance to all moving or hot components.
- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.
- Remove the intake tube between the Mass Airflow (MAF) sensor (G70) and intake scoop. Loosen the hose clips with hose clip pliers (VAS 6362).
- Disconnect the orange connector for the Exhaust Gas Temperature (EGT) sensor 2 (G448) - 1 - and the black connector for the Heated Oxygen Sensor (HO2S) (G39) - 3 - on the plenum chamber bulkhead.
- Disconnect the brown connector for the Exhaust Gas Temperature (EGT) sensor 3 (G495) - 1 - (secured behind the bracket).
- Guide the wires out of the mount - 2 - on the plenum chamber bulkhead and on the turbocharger.
- Disconnect the connector - 2 - from exhaust pressure sensor 1 (G450) - 1 -.
- Remove the bolt - 4 - and bracket - 3 - with the exhaust pressure sensor 1 - 1 - in the - direction of the arrow - and lay them aside (the control wires remain connected).
- Remove the heat shield and disconnect the connector from the exhaust pressure sensor 2 (G451). Refer to one of the following:
• Engine code CBEA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
• Engine code CJAA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
- Remove the control line from the exhaust pressure sensor 2 (G451). Remove the spring clamp using hose clip pliers (VAS 6362). Refer to one of the following:
• Engine code CBEA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
• Engine code CJAA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
- Remove the bolts and bracket with the exhaust pressure sensor 2 and lay them aside (the control wire to the particulate filter remains connected).
- Remove the noise insulation.
- Remove the right drive axle heat shield bolts - arrows - and shield.
- Remove the lower bracket for the particulate filter. Refer to one of the following:
• Engine code CBEA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
• Engine code CJAA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
• Remove the nuts above the bracket with the wrench SW13 (T10384).
- Remove the EGR filter.
- Remove the particulate filter from the upper bracket and remove the bracket on the cylinder head. Refer to one of the following:
• Engine code CBEA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
• Engine code CJAA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
- Remove the clamp between the particulate filter and turbocharger. Refer to one of the following:
• Engine code CBEA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
• Engine code CJAA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
- Remove the nuts - arrows - and slightly pull the underbody cover downward.
• Route the wires as indicated. Refer to => [ Exhaust System Component Wire Routing ] Exhaust System Component Wire Routing.
- Disconnect the orange connector for the Exhaust Gas Temperature (EGT) sensor 4 (G648) - 1 - and the brown connector for the Oxygen Sensor (O2) after Three Way Catalytic Converter (G130) - 3 -.
- Remove the connector from the bracket - 2 - and guide the lines out on the underbody - arrows -.
- Remove the NOx reduction catalytic converter mount on the subframe. Refer to one of the following:
• Engine code CBEA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
• Engine code CJAA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
- Lower the subframe approximately 6 cm.
- Remove the tunnel bridge. Refer to one of the following:
• Engine Code CBEA, refer to => [ Muffler Overview ] Muffler Overview.
• Engine Code CJAA, refer to => [ Muffler Overview ] Muffler Overview.
- Remove the clamp between the NOx reduction catalytic converter and the exhaust door control unit (J883).
The decoupling elements between the particulate filter and NOx reduction catalytic converter can be damaged. When removing and installing:
• Do not bend the decoupling element more than 10°.
• Do not stretch the decoupling element.
• Do not damage the wire mesh on the decoupling element.
• Use the transportation lock (T10404) to secure the unlocking element from overbending.
Vehicles with Engine Code CJAA:
- Disconnect the clamp between the NOx reduction catalytic converter and the particulate filter and remove the NOx reduction catalytic converter.
Continuation for all Engine Codes
- Remove the particulate filter. Be careful of the electrical wires and components.
Installing
• After installing the particulate filter with NOx reduction catalytic converter, make sure it is free of tension.
• Always replace self-locking nuts, seals, gaskets and clamps.
The decoupling elements between the particulate filter and NOx reduction catalytic converter can be damaged. When removing and installing:
• Do not bend the decoupling element more than 10°.
• Do not stretch the decoupling element.
• Do not damage the wire mesh on the decoupling element.
• Use the transportation lock (T10404) to secure the unlocking element from overbending.
Vehicles with Engine Codes CBEA:
- Bring the particulate filter with NOx reduction catalytic converter into its installation position. Be careful of the electrical wires and components.
Vehicles with engine Code CJAA:
- Install the particulate filter. Be careful of the electrical wires and components.
Continuation for all Engine Codes
- Install the subframe.
- Install a new seal between the NOx reduction catalytic converter and the exhaust door control unit (J883). Refer to => [ Installing the Seal Between the Exhaust
Door Control Unit and NOx Reduction Catalytic Converter ] Exhaust Door Control Unit (J883) and Reduction Catalytic Converter Overview.
- Install the new clamp between the NOx reduction catalytic converter and the exhaust door control unit.
Make sure the clamp is in the correct installed position. Refer to => [ Installed Position of the Clamp between
the Exhaust Door Control Unit and NOx Reduction Catalytic Converter ] Exhaust Door Control Unit (J883) and Reduction Catalytic Converter Overview.
Tightening specifications, refer to one of the following:
• Engine code CBEA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
• Engine code CJAA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
Vehicles with Engine Code CJAA.
- Install the new seal between the NOx reduction catalytic converter and the particulate filter.
- Install the new clamp between the NOx reduction catalytic converter and the particulate filter.
Make sure the clamp is in the correct installed position. Refer to => [ Clamps and Exhaust Gas Temperature Sensor, Installed Position ] Clamps and Exhaust Gas Temperature Sensor, Installed Position.
Continuation for all Engine Codes
- Install the tunnel bridge:
• Tightening specifications, refer to one of the following:
• Engine Code CBEA, refer to => [ Muffler Overview ] Muffler Overview.
• Engine Code CJAA, refer to => [ Muffler Overview ] Muffler Overview.
The additional numbered steps must be followed to ensure the particulate filter with the NOx reduction catalytic converter is installed correctly:
- Position the lower bracket with the nuts on the cylinder block and on the particulate filter. (Do not tighten the nuts.)
- Position the new clamp with a new gasket between the particulate filter and turbocharger (do not tighten the clamp):
• Make sure the clamp is in the correct installed position. Refer to => [ Clamps and Exhaust Gas Temperature Sensor, Installed Position ] Clamps and Exhaust Gas Temperature Sensor, Installed Position.
- Install the EGR filter.
- Position a new clamp between the particulate filter and EGR filter (do not tighten the clamp):
• Make sure the clamp is in the correct installed position. refer to => [ Clamps and Exhaust Gas Temperature Sensor, Installed Position ] Clamps and Exhaust Gas Temperature Sensor, Installed Position.
- Mount the particulate filter on the upper bracket but do not tighten the bolt yet.
- Tighten the mounting elements in the following sequence:
- NOx reduction catalytic converter mount on the subframe:
- Clamp between the particulate filter and turbocharger.
- Lower bracket to the cylinder block:
- Lower bracket to the particulate filter:
- Upper bracket to the particulate filter:
- Upper bracket to the cylinder head:
- Clamp between the particulate filter and exhaust gas recirculation filter:
• Tightening specifications, refer to one of the following:
Engine code CBEA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
Engine code CJAA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
If the particulate filter was replaced:
- Remove the transport and protective packaging on the decoupling element between the particulate filter and NOx reduction catalytic converter.
Further installation is performed in reverse order. When doing this note the following:
• Make sure lines connections are securely fastened.
• Tightening specifications, refer to one of the following:
Engine code CBEA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
Engine code CJAA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
- Install the right drive axle heat shield and bolts - arrows -.
• If the particulate filter was replaced, then the adaptation of the soot load measurement must be set to "0". Refer to "Guided Functions" in the vehicle diagnostic tester.
- Perform a road test. The vehicle must be aligned if the steering wheel is crooked.
- Install the engine cover. Refer to => [ Engine Cover ] Engine Cover.