Continuous Trap Oxidizer: Service and Repair
Particulate Filter with NOx Absorption Catalytic Converter
• Turbocharger and components overview. Refer to => [ Turbocharger and Components Overview ] Turbocharger and Components Overview.
• Exhaust door control unit with NOx reduction catalytic converter overview. Refer to => [ Exhaust Door Control Unit with NOx Reduction Catalytic Converter Overview ] Exhaust Door Control Unit With NOx Reduction Catalytic Converter Overview.
• After installing the particulate filter with NOx reduction catalytic converter, make sure it is free of tension.
• Replace the self-locking nuts, the seals, the gaskets and clamps.
• Hose connections are secured with either spring type or clamp type clamps.
• Replace the locking clamps with spring clamps.
• Hose clip pliers (VAS 6362) or (VAS 6340) are recommended for installing spring clamps.
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-/Gearbox 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.
• Particulate filter with NOx reduction catalytic converter overview. Refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter With NOx Reduction Catalytic Converter Overview.
Removing
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.
• Ensure sufficient clearance to all moving or hot components.
- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.
- Remove the intake hose between the Mass Airflow (MAF) sensor and adapter. Loosen the hose clamps using the hose clamp pliers (VAS 6362).
- Disconnect the "orange" connector for the exhaust gas temperature sensor 2 (- 1 -) and the "black" connector for the heated oxygen sensor (- 3 -) on the plenum chamber bulkhead.
- Disconnect the "brown" connector for the exhaust gas temperature sensor 3 (- 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 the differential pressure sensor - 1 -.
- Remove the bolt - 4 - and bracket - 3 - with the differential pressure sensor - 1 - in the - direction of the arrow - and lay them aside (the control lines remain connected).
- Remove the heat shield and disconnect the connector from the exhaust pressure sensor 1. Refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter With NOx Reduction Catalytic Converter Overview.
- Disconnect the control line from exhaust pressure sensor 1. Remove the clip using hose clamp pliers (VAS 6362).
- Remove the bolts and bracket with the exhaust pressure sensor 1 and lay them aside (the control line 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 => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter With NOx Reduction Catalytic Converter Overview.
• Remove the nuts above the bracket using the wrench SW13 (T10384).
- Remove the Exhaust Gas Recirculation (EGR) filter, see - item 9 - in the => [ Exhaust Gas Recirculation System Component Overview ] Service and Repair.
- Remove the particulate filter from the upper bracket and remove the bracket from the cylinder head. 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 => [ 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 ] Description and Operation.
- Disconnect the "orange" connector for the exhaust gas temperature sensor 4 (- 1 -) and the "brown" connector for the oxygen sensor after three way catalytic converter - 3 -.
- Remove the connector from the bracket - 2 - and guide the wires out of the underbody - arrows -.
- Remove the NOx reduction catalytic converter mount on the subframe. Refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter With NOx Reduction Catalytic Converter Overview.
- Lower the subframe approximately 6 centimeters (cm).
- Remove the tunnel brace.
- Remove the clamp between the NOx reduction catalytic converter and the exhaust door control unit.
The coupling elements between the particulate filter and NOx reduction catalytic converter can be damaged. When removing and installing:
• Do not bend the coupling element more than 10°.
• Do not stretch the coupling element.
• Do not damage the wire mesh on the coupling element.
• Use the transportation lock (T10404) to secure the unlocking element from over-bending.
- Disconnect the clamp between the NOx reduction catalytic converter and the particulate filter and remove the NOx reduction catalytic converter.
- 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.
• Replace the self-locking nuts, the seals, the gaskets and clamps.
The coupling elements between the particulate filter and NOx reduction catalytic converter can be damaged. When removing and installing:
• Do not bend the coupling element more than 10°.
• Do not stretch the coupling element.
• Do not damage the wire mesh on the coupling element.
• Use the transportation lock (T10404) to secure the unlocking element from over-bending.
- Install the particulate filter. Be careful of the electrical wires and components.
- Install the subframe.
- Install a new seal between the NOx reduction catalytic converter and the exhaust door control unit. => [ Installing the Seal between the Exhaust Door Control Unit and Exhaust Pipe with Catalyst and Particulate Filter or the NOx Reduction Catalytic Converter ] Exhaust Door Control Unit With NOx 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 or Exhaust Pipe with Catalyst and Particulate Filter ] Exhaust Door Control Unit With NOx Reduction Catalytic Converter Overview.
Tightening specification, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter With NOx Reduction Catalytic Converter Overview.
- 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 installation position. Refer to => [ Clamps and Exhaust Gas Temperature Sensor, Installed Position ] Service and Repair.
Tightening specification, see - item 18 - in the => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter With NOx Reduction Catalytic Converter Overview.
- Install the tunnel brace:
• Tightening specification, refer to => [ Muffler and Mounts Overview ] Service and Repair.
The additional numbered steps must be followed to ensure the particulate filter with NOx reduction catalytic converter is installed correctly:
- Position the lower bracket with the nuts to the cylinder block and the particulate filter. (Do not tighten the nuts.)
- Position the new clamp with a new seal 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 ] Service and Repair.
- Install the EGR filter, see - item 9 - in the => [ Exhaust Gas Recirculation System Component Overview ] Service and Repair.
- 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 ] Service and Repair.
- Position the particulate filter on the upper bracket with the bolt. (Do not tighten the bolt.)
- Tighten the bolts in the following sequence:
- NOx reduction catalytic converter mount to 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 EGR filter:
• Tightening specifications, 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 coupling element between the particulate filter and NOx reduction catalytic converter.
Further installation is in the reverse order of removal. Note the following:
• Make sure the wires connections are securely fastened.
• Tightening specifications, 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.