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-/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.
• Turbocharger and exhaust manifold with 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 the following:
• 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 and reduction catalytic converter overview. Refer to => [ Exhaust Door Control Unit and Reduction Catalytic Converter Overview ] Exhaust Door Control Unit and Reduction Catalytic Converter Overview.
• Hose connections are secured with either spring type or clamp type clamps.
• Always replace clamp type clamps with spring type clamps.
• Hose clip pliers (VAS 6362) or (VAS 6340) are recommended for installing spring type 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 and intake scoop. Loosen the hose clamps using hose clip 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 exhaust pressure sensor 1 (- 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. Refer to the following:
• 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. Remove the spring clamp using hose clip pliers (VAS 6362). Refer to the following:
• 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 right drive axle from the transmission flange.
- Carefully lay the drive axle on the subframe.
- Remove the lower bracket for the particulate filter. Refer to the following:
• 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 the following:
• 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 the following:
• 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 ] 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 lines out on the underbody - arrows -.
- Remove the NOx reduction catalytic converter mount on the subframe. Refer to the following:
• 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 brace. Refer to the following:
• Engine Code CJAA, refer to => [ Muffler Overview ] Service and Repair.
- 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.
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
- 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 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.
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.
with engine Code CJAA
- Install the particulate filter. Be careful of the electrical wires and components.
Continuation for All
- Install the subframe.
- Install a new seal between the NOx reduction catalytic converter and the exhaust door control unit. Refer to => [ Installing the Seal Between the Exhaust Door Control Unit and NOx Reduction Catalytic Converter ] Exhaust Door Control Unit 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 and Reduction Catalytic Converter Overview.
Tightening specifications, refer to the following:
• Engine code CJAA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
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
- Install the tunnel bridge:
• Tightening specifications, refer to the following:
• Engine Code CJAA, refer to => [ Muffler Overview ] Service and Repair.
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 the following:
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 coupling element between the particulate filter and NOx reduction catalytic converter.
Further installation is performed in the reverse order. When doing this note the following:
• Make sure lines connections are securely fastened.
• Tightening specifications, refer to the following:
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.