Circular - Emiss

Emissions Recall
Code: 23V5
REVISION
Subject
Release Date
Revision Summary
Affected Vehicles
3.0L TDI Engine – Emissions System Modification – Customer Only (Retail Sold) TDI
Vehicles USA ONLY
November 9, 2017
Updated work procedure and added link to repair video.
U.S.A.:
2013-2015 MY Audi Q7 3.0L TDI Generation 2.1
Check Campaigns/Actions screen in Elsa on the day of repair to verify that a VIN qualifies for repair under this
action. Elsa is the only valid campaign inquiry & verification source.

Campaign status must show “open.”

If Elsa shows other open action(s), inform your customer so that the work can also be completed at
the same time the vehicle is in the workshop for this campaign.
Problem Description
3.0L TDI vehicles were equipped with undisclosed Auxiliary Emission Control Devices which
are not permitted by emissions regulations.
Corrective Action
Install updated engine control module (ECM) software, transmission control module (TCM)
software and hardware to bring affected vehicles into regulatory compliance.
Code Visibility
On or about November 6, 2017, affected vehicles were listed on the Inventory Vehicle Open
Campaign Action report under My Dealership Reports. A list was not posted for dealers who did
not have any affected vehicles. The campaign code showed open on affected vehicles in Elsa
and affected vehicles are identified with this campaign code in the VIN Lookup tool at
www.audiusa.com.
Owner Notification
Emissions Campaigns
Requirements
(CALIFORNIA ONLY)
Loaner/Rental Vehicle –
REQUIRED!
Owner notification took place on November 6, 2017.
The California Air Resources Board and the Department of Motor Vehicles (DMV) require
emissions-related campaigns to be completed prior to vehicle registration renewal. When
campaign work is done you must provide the owner with a signed “Vehicle Emission Recall –
Proof of Correction” certificate (RC EMISCAVWAU). Order certificates online via the
Compliance Label Ordering portal at www.accessaudi.com.
Customers are eligible to receive a loaner vehicle. Please refer to the warranty extension
bulletin AWA 17-13 for claiming instructions.
To remain compliant with the Settlement Agreement, Service Consultants must complete a
Loaner/Rental label and it must be signed by the customer. This documents each customer’s
decision to accept or decline the offer for a loaner or rental vehicle while the Approved
Emissions Modification was being performed on their vehicle.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Audi dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 1 of 35
Affix the completed label to the Repair Order and follow the new photo documentation
requirements for this label in the IN-FORM tool.
Additional Information
Please alert everyone in your dealership about this action, including Sales, Service, Parts
and Accounting personnel. Contact Warranty if you have any questions.
Fill out and affix the appropriate TDI Recall Proof of Completion label and the appropriate
Supplemental Vehicle Emissions Control Information Label after work is complete. Additional
shipments will be released based on the volume of completed repairs claimed through
SAGA. The parts will not be available for order through the website at this time.
The information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures
are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether
this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 2 of 35
Claim Entry Instructions
After campaign has been completed, enter claim as soon as possible to help prevent work from being duplicated
elsewhere. Attach the Elsa screen print showing action open on the day of repair to the repair order.
If customer refused campaign work:
 U.S. dealers: Submit the request through Audi Warranty Online under the Campaigns/Update option.
Service Number
23V5
Damage Code
0099
Parts Vendor Code
Claim Type
Causal Indicator
Vehicle Wash/Loaner
Criteria I.D.
002
Sold vehicle: 7 10
Mark 3.0L Gen 2.1 Kit as causal*
Do not claim vehicle wash/loaner under this action
01
MY 2013/2014:
Install 3.0L Gen 2.1 Kit, install Glow Plug with Combustion Chamber Pressure Sensor,
Top off AdBlue tank, and *install a supplemental Vehicle Emissions Control
Information label and TDI Emissions Modification Proof of Completion Label.
Labor operation: 2674 19 99
Quantity
1.00
1.00
Part Number
4L0298099 X
059905061H
Up to 14.00
G 052910A2
155 T.U.
Description
3.0L Gen 2.1 Kit*
Glow Plug with Combustion Chamber
Pressure Sensor
AdBlue (one bottle = 0.5 gallon/ 1.89 Liter)
--AND-Connect battery charger.
Labor operation: 2706 89 50
10 T.U.
--AND-Connect vehicle diagnostic tester, perform software update for control unit.
Labor operation: 2360 22 99
Time stated on diagnostic protocol
(Maximum 60 T.U.)
--AND-Follow IN-FORM tool app.
Labor operation: 0183 00 99
20 T.U.
*Labels are sent free of charge. They cannot be charged to this campaign.
Continue to next page
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 3 of 35
Criteria I.D.
02
MY 2015:
Install 3.0L Gen 2.1 Kit, top off AdBlue tank, and *install a supplemental Vehicle
Emissions Control Information label and TDI Emissions Modification Label.
Labor operation: 2674 20 99
Quantity
1.00
Up to 14.00
Part Number
4L0298099 X
G 052910A2
135 T.U.
Description
3.0L Gen 2.1 Kit
AdBlue (one bottle = 0.5 gallon/ 1.89 Liter)
--AND-Connect battery charger.
Labor operation: 2706 89 50
10 T.U.
--AND-Connect vehicle diagnostic tester, perform software update for control unit.
Labor operation: 2360 22 99
Time stated on diagnostic protocol
(Maximum 60 T.U.)
--AND-Follow IN-FORM tool app.
Labor operation: 0183 00 99
20 T.U.
*Labels are sent free of charge. They cannot be charged to this campaign.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 4 of 35
Campaign Work Procedure
23V5 Emissions Recall
At this time, affected new and used vehicles in dealer inventory are not
included in this emissions modification release.
NOTE
Damages resulting from improper repair or failure to follow these work instructions are the dealer’s responsibility
and are not eligible for reimbursement under this action.
Required Parts
Criteria
01, 02
01
01, 02
Quantity
1
1
up to 23.0L
Part Description
3.0L Gen 2.1 Kit
Glow Plug with Combustion Chamber Pressure Sensor
AdBlue
Part Number
4L0298099 X
059905061H
G 052910A2
Required Labels
Quantity
1
Part Description
TDI Proof of Completion Label
1
TDI Proof of Completion Label
1
VECI Label
1
VECI Label
1
VECI Label
Part Number
4L0 010 023 B
--OR-4L0 010 023 A
--AND-059 010 533 BH
--OR-059 010 533 BJ
--OR-059 010 533 BK
Vehicle
MY 2013 and 2014 Q7
MY 2015 Q7
MY 2013 Q7
MY 2014 Q7
MY 2015 Q7
IMPORTANT!
Maintaining Your TDI Campaign Label Supply
•
SAGA claims count! Warranty Administrators should enter TDI claims promptly to ensure
labels can be allocated to support future repairs.
•
TDI Labels are allocated daily, free of charge, based on the count of TDI claims entered in
SAGA.
•
TDI labels cannot be ordered through the Compliance Label Ordering Portal. If you have
questions, please email [email protected].
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 5 of 35
Required Tools
VAS6150D - Diagnostic
Tester (or equivalent)
VAS6154 - Vehicle
Communication
Interface (or equivalent)
GRX3000VAS – Battery
Tester/Charger (or
equivalent)
Diesel Engine Tool Set
- 17mm -T10395A(or equivalent)
Ring Wrench 7-Piece Set
-3337(or equivalent)
Glow Plug Socket
– VAS6454
(or equivalent)
Torque Wrench 1331
5-50Nm -VAG 1331
(or equivalent)
Torque Wrench 1332
40-200Nm -VAG 1332
(or equivalent)
Engine Bung Set
-VAS6122(or equivalent)
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 6 of 35
•
Service Modification Validation Web App
•
tdi-inform.track360.com
TIP
This web application is compatible with desktops,
laptops, Apple and Android mobile devices running the
most current versions of FireFox, Chrome, Safari, or
Explorer as well as iOS 9+ on iPads and iPhones.
NOTE
RISK of Non-payment!
Not using the IN-FORM tool to document and validate
the modification will stop the processing of payment for
your dealership even if the modification has been
completed. Look for the image below to indicate labor
operations, parts, or labeling that requires
IN-FORM tool image documentation.
Emissions Modification Instruction
Section A - Check for Previous Repair
•
Enter the VIN in Elsa and proceed to the
“Campaign/Action” screen.
TIP
On the date of repair, print this screen and keep a copy
with the repair order.
•
Confirm the Campaign/Action is open .
If the status is closed, no further work is required.
•
Note the Applicable Criteria ID  for use
in determining the correct work to be done and
corresponding parts associated.
•
Check for other Open campaign actions .
•
Other Open campaign actions must be completed
prior to releasing the vehicle to the customer.
Proceed to Section B
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 7 of 35
Section B – Check for Service Initiation
NOTE
RISK of Non-payment!
Not using the IN-FORM tool to document and validate
the modification will stop the processing of payment
for your dealership even if the modification has been
completed. Look for the image below to indicate
labor operations, parts, or labeling that requires
IN-FORM tool image documentation.
NOTE
RISK of Non-payment!
Ensure that the “check mark”  is present
prior to beginning any repair.
•
Check the Service Initiation Form for the
presence of the “check mark” .
o
If “check mark”  is NOT
present, DO NOT proceed with any
repair.
o
If “check mark”  is present,
initiate Service Modification
Documentation Form and continue
work.
DO NOT proceed with any work unless you can
initiate the Service Modification Documentation
Form.
Proceed to Section C
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 8 of 35
Section C – Check for Pre-existing MIL ON conditions and Vehicle Modifications
•
Perform a visual inspection of the intake,
exhaust, and emissions systems.
o If the visual inspection of the intake, exhaust,
or emissions equipment reveals damage or
concerns, STOP, create an ATA ticket and
contact the Audi Technical Assistance.
o If the visual inspection of the intake, exhaust,
or emissions equipment reveals no damage
or concerns, continue the work procedure.
•
Check for vehicle modifications from original
equipment.
o If vehicle modifications from original
equipment related to emissions components
are found, STOP, create an ATA ticket and
contact the Audi Technical Assistance.
o If vehicle modifications from original
equipment related to emissions components
are not found, continue the work procedure.
•
Check for illumination of the MIL .
o If MIL is illuminated, STOP, create an ATA
ticket and contact the Audi Technical
Assistance.
o If MIL is not illuminated, continue the work
procedure.
TIP
ATA cases regarding MIL ON conditions require a GFF
diagnostic log to be uploaded at the time of first contact.
NOTE
RISK of Non-payment!
The purpose for this step is to document vehicle
condition prior to initiation of this action and does
not authorize the repair of any pre-existing
conditions.
Proceed to Section D
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 9 of 35
Section D – Install Hardware
WARNING
Risk of injury. Refer to “Warning and Safety Precautions”, found in Appendix A at the end of this document.
NOTE
•
If the vehicle is equipped with air suspension, vehicle lift mode must be activated before raising vehicle with
vehicle jack or hoist so that the air suspension automatic control procedures do not create difficulties.
•
Vehicle lift mode is automatically switched off at a speed above 6 mph.
•
Fill the AdBlue tank to maximum fill line.
o
AdBlue filler is located behind the fuel
door.
Part Number
G 052 910 A2
Description
AdBlue
Quantity
Up to 23.0L
If equipped with air suspension:
•
Turn on the ignition.
•
Press “CAR” function button . “adaptive air
suspension” main menu appears.
•
Press “SETUP” function button. “adaptive air
suspension” menu appears.
•
Rotate control knob  to “Vehicle Lifting Mode”
and select “ON”.
•
Raise the vehicle on hoist to desired level.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 10 of 35
For Criteria 01 ONLY:
Install Glow Plug with
Combustion Chamber Pressure Sensor (MY 20132014)
•
Carefully remove the engine cover from the 4 bolts
 one after the other. Do not remove the
engine cover on one side or in a jerking manner.
•
Disconnect the glow plug connector <1> from
Cylinder 2 Glow Plug with Combustion Chamber
Pressure Sensor -G678- <2>.
•
Clean the glow plug duct in the cylinder head
(contaminants must not fall into the cylinder).
NOTE
Examples for cleaning:
•
Extract large contaminants with a vacuum
cleaner.
•
Spray a brake cleaner or another suitable
cleaner into the glow plug shaft, let it work and
then use compressed air to remove it.
•
Then clean the glow plug duct with a rag
dampened with oil.
•
Loosen the Cylinder 2 Glow Plug with Combustion
Chamber Pressure Sensor -G678- <2> using
Glow Plug Socket - VAS6454.
•
Carefully remove the Cylinder 2 Glow Plug with
Combustion Chamber Pressure Sensor -G678- by
hand or with a hose without bending it.
•
Carefully install the new the Cylinder 2 Glow Plug
with Combustion Chamber Pressure Sensor
-G678- <2> by hand or with a hose without
bending it.
Part Number
059 905 061 H
Description
Glow Plug with
Combustion Chamber
Pressure Sensor
Quantity
1
•
Using Glow Plug Socket - VAS6454, tighten to 17
Nm.
•
Reconnect the glow plug connector <1> from
Cylinder 2 Glow Plug with Combustion Chamber
Pressure Sensor -G678- <2> and make sure it is
secure.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 11 of 35
NOTE
•
•
In order to prevent damage, do not hit the
engine cover with your fist or tool.
•
Be sure not to place the engine cover on the oil
filler tube.
Reinstall the engine cover by first pushing the
cover with both hands into the rubber grommets in
the rear and then into the rubber grommets in the
front.
All models, continue to the next step.
Figure 
Remove the NOx #2 sensor
<1> from the catalyst pipe.
Figure 
Cover the NOx #2 Sensor
with a plastic bag (or
equivalent) and secure it
out of the way with a tie
strap
(or
equivalent)
attached through either one
of two holes in the rear
driveshaft
mid-bearing
bracket .
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 12 of 35
Figure 
Remove the PM Sensor
<1> from the SCR Catalyst
pipe.
Figure 
Disconnect the electrical
connection at the PM
Sensor Module <2>.
Remove the two nuts <3>
securing the PM Sensor
Module to the bracket.
Figure 
Remove the PM Sensor
wiring harness from the
securing clips and tie
straps, and then remove the
and
sensor,
module,
harness from the vehicle as
an assembly. Route the
wiring harness up and over
the exhaust bracket .
•
Loosen the screw  and remove the clamp from
the Reducing Agent Injector -N474-.
•
Leave the electrical connector and the Reducing
Agent Injector AdBlue feed line connected at this
This will reduce the possibility of
time.
contaminating the electrical connection with
AdBlue.
•
Secure the Reducing Agent Injector out of the way
with a tie strap (or equivalent).
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 13 of 35
•
Loosen the two nuts on the Dual Clamp 
so the clamp can slide back and forth on the
exhaust pipe.
•
Leave the clamp in the installed position at this
time. This will assist in holding the SCR Catalyst
in place while removing the brackets in the next
step.
•
With the assistance of a second technician,
remove the three nuts  from the exhaust studs
securing the SCR Catalyst to the Diesel
Particulate Filter (DPF).
•
Remove the bolts from SCR Catalyst brackets at
locations  with assistance from second
technician to support the SCR Catalyst while the
brackets are removed.
•
Slide the Dual Clamp  towards the rear of the
vehicle, and with the assistance of a second
technician, remove the SCR Catalyst from the
vehicle.
•
Remove the Dual Clamp  from the exhaust
pipe and discard.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 14 of 35
NOTE
STOP!
Due to corrosion, one or more of the mounting studs
may break  when removing the SCR catalytic
converter from the Diesel Particulate Filter (DPF) flange.
DO NOT use a hammer and punch, heat, torch, air
hammer, or other method to remove the studs from
the DPF flange.
Consequential damage to Exhaust Gas Temperature
Sensors, Diesel Particulate Filter, AdBlue Injector Feed
Line, or any other ancillary components WILL NOT BE
COVERED under this action due to damage from heat,
impact, or vibration.
•
If stud replacement is necessary, IT IS
REQUIRED to use a press tool such as the OTC
5057 clevis pin press (or equivalent), or other
available screw or hydraulic type clevis/stud press
tool to remove all necessary studs from the rear
DPF flange.
o
It is advised if one stud breaks that all
three studs are pressed out and replaced
with the bolts/nuts included in the parts
kit.
o
For best results, cut any studs that do not
break off as close to the flange as
possible. Pressing a full length stud
increases the chance of bending the stud,
which may complicate the removal
process.
o
Use a cap from the VAS 6122 Engine
Bung Set (or equivalent) to cover the hole
in the DPF to eliminate the chance of
contaminating of the DPF substrate with
metallic particles when cutting the studs.
OTC 5057 Clevis Pin Press
Scan this QR Code or copy/paste the link below
into your internet browser to see a short video
explaining this procedure:
https://audiexternal.kzoplatform.com:443/swf/player/356
•
Install the replacement bolts and corresponding
nuts into the rear DPF flange.
Part Number
Description
Quantity
N 01024713
Replacement Exhaust Bolt
3
N 91130802
Shouldered Hex Nut
3
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 15 of 35
NOTE
Coat the threads on the nuts and exhaust studs/bolts
 with hot bolt paste prior to installation. Refer to the
Parts Catalog.
•
Install the new exhaust Dual Clamp onto the
exhaust pipe at location  and slide the clamp
to the rear of the vehicle, but do not tighten.
•
With the assistance of a second technician, install
the new SCR Catalyst with a new gasket between
the SCR Catalyst and DPF . Fit the SCR
Catalyst onto the DPF flange studs/bolts and
install new nuts and tighten to 23 Nm.
•
Slide the Dual Clamp into the installed position on
the SCR Catalyst, but do not tighten. This will
assist in holding the SCR Catalyst in place while
the exhaust system is properly tensioned.
•
Install the bolts for the SCR Catalyst brackets  and tighten by hand.
Part Number
Description
Quantity
7P0 254 400 BX
Exhaust Pipe With
Catalyst And Adapters
1
1K0 253 141 J
Dual Clamp
1
7L5 253 115 C
Gasket
1
N 911 308 02
Shouldered Hex Nut
3
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 16 of 35
•
Tighten the Dual Clamp  until there is a slight
dragging resistance on both the SCR Catalyst
pipe  and the rear resonator/muffler
pipe , but do not tighten so much that
the pipes cannot slide in and out of the Dual
Clamp .
•
Pretension the rear resonator/muffler hanging
straps by pulling the rear resonator/muffler pipe
towards the front of the vehicle  and
pulling the SCR Catalyst pipe towards the rear of
the vehicle .
In order to reduce harmonic
vibration,
the
rear
muffler/resonator
straps
 require 12 mm of
forward tension, as shown
Pull
in the sub-photo.
forward
on
the
rear
muffler/resonator pipe and
insert the pipe deeper into
the Dual Clamp until this
dimension is achieved.
 = Rear Resonator Hanging Straps
•
Once the desired
dimension of  =
12 mm is achieved,
tighten the Dual
Clamp nuts to 23
Nm.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 17 of 35
Figure 
Front
Muffler/Resonator
hanging strap:  = 4 mm
If necessary, loosen the
bolts
at
the
forward
resonator pipe hanging
strap  and adjust the
bracket until  = 4 mm of
forward tension.
•
Figures 
Tighten the two
hanging strap bolts
to 23 Nm.
Left and Right SCR hanging
straps:  = 0.00 mm,
install without tension.
If necessary, loosen the
bolts at the left and right
SCR Cat hanging straps  and adjust the
brackets until  = 0.00
mm. The SCR Catalyst
hanging straps are installed
tension free.
•
•
Tighten the two
hanging
strap
bracket bolts 
to 60 Nm.
•
Tighten the two
hanging
strap
bracket bolts 
to 23 Nm.
If necessary, align the tail pipes by first loosening
the screw-type clamp  on the tailpipes.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 18 of 35
•
Align tail pipe to the rear muffler and center the tail
pipes into the bumper cover.
•
Check distance of left and right tail pipes to
bumper.
o
•
Dimension -x- left = dimension -x- right
Once the tail pipe is properly aligned to the
bumper cover, tighten the screw-type clamps
 to 60 Nm.
NOTE
•
Lay a cloth below the Reducing Agent Injector
to catch any escaping AdBlue reducing agent.
•
Make certain the electrical connector is
installed into the new Reducing Agent Injector
-N474- before disconnecting the AdBlue
reducing agent feed hose. This will reduce the
possibility of contaminating the electrical
connection with AdBlue.
Part Number
4H0 131 113 A
Description
Quantity
Injector For Reduction
Agent
1
•
Disconnect the electrical connector <2> from the
existing Reducing Agent Injector -N474- <4>.
•
Connect the connector <2> to the new Reducing
Agent Injector -N474- <4> and set it aside.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 19 of 35
•
Make certain the electrical connector is installed
into the new Reducing Agent Injector before
disconnecting the AdBlue reducing agent feed
hose.
This will reduce the possibility of
contaminating the electrical connection with
AdBlue.
•
Remove the AdBlue reducing agent feed hose
<1> by pressing the release clasps  and
remove the reducing agent hose <1>.
•
Connect the AdBlue reducing agent hose <1> to
the new Reducing Agent Injector -N474- <4>.
•
Install the new Reducing Agent Injector -N474into the SCR Catalyst pipe ensuring that the tabs
on the Injector  fit into the corresponding
mounts in the SCR catalytic converter.
TIP
The gasket comes pre-installed on the new Injector.
Verify the new gasket is present and seated properly
before installation.
•
Install a new retaining clamp  and tighten the
bolt to 5 Nm.
Part Number
3C0 253 725
Description
Quantity
Retaining Clamp
1
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 20 of 35
NOTE
•
•
Coat new PM Sensor -G784- <2> threads with
an assembly paste. Paste must not get on to
slits of sensor body. Refer to the Parts Catalog.
•
The sensor wire must always be attached at the
same location when installing. Do not let the
sensor cable come in contact with the exhaust
pipe.
Install the new PM Sensor -G784- <2> and tighten
to 50 Nm.
Part Number
059 906 261
Description
Quantity
PM Sensor
1
•
Recover all retention clips from the removed PM
Sensor harness and install them into the
appropriate locations on the chassis. A new tie
strap may be required for one retention clip.
•
Reinstall the PM Sensor control module
-G784- and the nuts . Tighten to 6 Nm.
•
Reconnect the PM Sensor connector <1>.
•
Capture a single photo showing both the new SCR
Catalyst and the new PM Sensor and upload the
photo to the TDI IN-FORM Tool.
•
See the example photo for proper orientation and
preferred photo angle.
This photo can be
captured in the air during the repair, or on the
ground after the repair as shown.
•
Switch off Vehicle Lift Mode by turning on the
ignition.
•
Press “CAR” function button . “adaptive air
suspension” main menu appears.
•
Press “SETUP” function button. “adaptive air
suspension” menu appears.
•
Rotate control knob  to “Vehicle lift mode” and
select “OFF” in order to switch off vehicle lift mode.
Proceed to Section E
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 21 of 35
Section E – Software Update Procedure
NOTE
Prior to launching the VAS Diagnostic Tester and starting an update, ensure the following conditions are met;
The ODIS software is completely up to date.

Refer to the “Alerts” section on ServiceNet home page for the current ODIS version.
The battery charger is connected to the vehicle battery and remains connected for the duration of the
software update.
•
Battery voltage must remain above 12.5 volts for the duration of the software update. Failure to
do so may cause the update to fail, which could result in damage to the control module. Control
modules damaged by insufficient voltage will not be covered.
The screen saver and power saving settings are off.
•
Failure to do so may result in the tester entering power save mode during the software update,
which could result in damage to the control module.
The VAS Diagnostic Tester is plugged in using the supplied power adapters.
•
Under no circumstances should the tester be used on battery power alone during the software
update. Failure to do so may result in the tester powering off during the update, which could result
in damage to the control module.
If using the Bluetooth VAS 5054A transmitter head, it is connected to the tester with a USB cable.
NOTE
Using Bluetooth for this action is PROHIBITED!
Damage caused to electronic components (e.g. ECM, TCM, etc.) during the SVM flash process is not covered.
•
Performing a software update using a Bluetooth connection increases the risk of losing connection
during the update, which could result in damage to the control module.
It also greatly increases the time required to perform the update. Requests for additional time or
parts will be denied if the GFF log shows the update was performed using Bluetooth.
The Bluetooth function of the scan tool is physically switched off .
VAS 6150 & VAS 6150A
VAS 6150B
VAS 6150C
(Front panel behind handle)
(Right side behind WIRELESS door)
(Left side behind SC/EX door)
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 22 of 35
WARNING
Radiator Fan(s) may cycle ON high speed during the Update Process! There is a serious risk that personal injury
may result if contact is made with spinning fan blades. Keep hands and all objects away from Radiator Fan(s) during
Update Process!
TIP
To Update-Programming using SVM, review and follow instructions in Technical Bulletin 2014603: Software Version
Management (SVM) Operating Instructions.
The SVM Process must be completed in its entirety so the database receives the update confirmation response. A
warranty claim may not be reimbursed if there is no confirmation response to support the claim.
Things to check before starting Software Version
Management (SVM):
Check and confirm that you have a LAN
connection .
Within the Connection Tab, verify that
the
Connection
type(s)
display
“Internet” .
Start a connections test  and
verify that all connections pass.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 23 of 35
•
Open the hood.
•
Open the battery cover.
•
Attach the GRX3000VAS Tester/Charger (or
equivalent) to the vehicle battery jump point and
ground jump point.
•
Switch the ignition on.
•
Apply the parking brake.
•
Switch the headlights off.
•
Connect the VAS6150X Diagnostic Tester (or
equivalent) to the vehicle.
•
Start the ODIS program.
NOTE
STOP!
All TDI flashes MUST be completed during a single,
standalone ODIS Diagnostic Session. You MUST fully
complete this campaign and send all GFF Paperless
logs before beginning any other campaigns or
operations. You MUST also conclude any other
campaigns or operations that have been started and
end the corresponding diagnostic session and send all
GFF Paperless logs before beginning this operation.
Failure to independently separate the ODIS diagnostic
session for this campaign will cause problems updating
the FAZIT server in Germany and will delay if not
negate the payment of the emissions modification.
IMPORTANT!
If there are any ODIS “Hot-Fix” patches installed, they
MUST be removed from the scan tool before beginning
this operation. ODIS “Hot-Fix” patches may affect the
flash process.
•
At this time, refer to the “Alerts” section of
ServiceNet to verify that the most recent version
of ODIS Software is loaded to the VAS6150X
Diagnostic Tester (or equivalent). Failure to flash
the vehicle using the most recent version of ODIS
Diagnostic Software will cause faults in certain
features of the flash operation.
•
Failure to validate the ODIS Diagnostic version
before flashing the vehicle may result in flash
failure, and may delay if not negate the payment
of the emissions modification.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 24 of 35
•
Confirm that scan tool is communicating with the
diagnostic head by USB .
o
•
If the Bluetooth symbol is shown  then disconnect the diagnostic
head from the vehicle and reconnect the
USB cable to the diagnostic head and
then reattach to the vehicle.
Upon ODIS startup, verify the “Diagnosis”
operating mode is selected .
NOTE
KESSY Vehicles!
It is REQUIRED to insert the key into the reader coil
, or place the key in the closest proximity
possible to the reader coil throughout the flash process.
NOTE
Before, during, and after the flash process and control
module interrogation phases, any number of instrument
cluster warning indicators (glow plug, check engine,
brake, ABS, etc) may illuminate, flash, or otherwise turn
on and off. It is also possible that other interior or
exterior components such as radio/infotainment
system, lamps, etc. may turn on and off. This is a
normal condition during this process. The illumination
of instrument cluster lamps (etc) will cease once the
ODIS session has ended and the ODIS diagnostic tool
is disconnected from the data port.
•
Upon ODIS startup, select “Diagnosis” .
•
Under the “Test Plan” tab, select “Self Test”
.
•
Select “Software Version Management”, then
select “SVM Code input” .
•
Select “Attach to the test plan” .
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 25 of 35
NOTE
RISK of Scan Tool Damage!
•
Do not leave the scan tool on the windshield during
the flash process, as it is possible that the
windshield wipers may cycle.
•
From the Test plan screen, Select “SVM Code
input” test plan , then select “Perform
test” .
•
Follow the on-screen prompts.
•
Enter the corrective action code (SVM code)
 as listed below.
SVM code
23V5A660
•
Select “Accept”, and follow the on-screen prompts
to complete the flash.
NOTE
•
It is IMPERATIVE that ALL of the ignition
cycle on/off delay requests are fulfilled in their
entirety during this flash process .
•
Failing to wait for the ignition on/off timing
cycle to complete (progress bar and
countdown timer ) before cycling the
ignition on/off MAY damage a control module.
•
Damage to control modules as a result of
failing to wait the specified time displayed by
the progress bar and countdown timer
 are NOT covered under this action.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 26 of 35
•
At the end of the diagnostic session, Select “Send”
 and follow the prompt for sending the log
on-line.
NOTE
RISK of Non-payment!
Diagnosis logs must be sent on-line after the flash
process to be considered for reimbursement.
TIP
Technicians may find it helpful to also store the log on
a USB stick for back-up.
Proceed to Section F.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 27 of 35
Section F – Supplemental Vehicle Emissions Control Information Label
Install Supplemental Vehicle Emissions Control
Information Label
TIP
•
The surface where the label is to be installed
must be clean, dry, and free from oil residue
prior to installing the label.
•
Label must NOT cover any existing label(s).
•
Label must be installed in location shown.
•
Photo documentation of label installed is
required.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 28 of 35
•
Open the hood.
•
Clean the surface where the label is to be
installed .
•
Install the Supplemental Vehicle Emissions
Control Information (VECI) label according to the
chart below on the underside of the hood or onto
the core support. The Supplemental Vehicle
Emissions Control Information (VECI) label and
TDI Recall Proof of Completion label should be
placed next to each other so that a single
photograph can capture both labels.
Vehicle
Label part number
MY 2013
059 010 533 BH
MY 2014
059 010 533 BJ
MY 2015
059 010 533 BK
NOTE
DO NOT Cover ANY existing labels!
Proceed to Section G
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 29 of 35
Section G – TDI Recall Proof of Completion Label
Install TDI Recall Proof of Completion label
TIP
•
The surface where the label is to be installed
must be clean, dry, and free from oil residue
prior to installing the label.
•
Label must NOT cover any existing label(s).
•
Photo documentation of label installed is
required.
•
Clean the surface next to the Vehicle Emission
Control Information Label where the TDI Recall
Proof of Completion label is to be installed.
•
Fill out completely the Recall Code, Dealer Code,
and Repair Date.
•
Affix the TDI Recall Proof of Completion label and
verify that the correct part number is being
installed according to chart below onto the
underside of the hood or onto the core support.
The TDI Recall Proof of Completion label and
Supplemental Vehicle Emissions Control
Information (VECI) label should be placed next to
each other so that a single photograph can
capture both labels.
Vehicle
Label part number
MY 2013 - 2014
4L0 010 023 B
MY 2015
4L0 010 023 A
NOTE
DO NOT Cover ANY existing labels!
•
Apply clear overlay (provided)
•
Close the hood
Proceed to Section H
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 30 of 35
Section H – Service Modification Documentation Requirements
Job Roles Summary:
•
Service Consultant – Initiates validation tool.
•
Service Technician –
modification requirements.
•
Manager – Validates the modification was properly
completed.
•
Dealer Representative/Cashier – Prints receipt,
fuel economy label and delivers to customer.
•
Warranty Administrator – Enters claim into the
SAGA system.
Completes
service
TIP
To access the interactive forms go to the TDI Settlement
Program microsite on vwhub.com. Then Select the “TDI
IN-FORM” Button from the lower left side of the microsite
navigation.
•
Enter the “TDI IN-FORM” tool 
•
Enter the VIN for the vehicle that requires
documentation.
TIP
The VIN can be manually typed in or using an iPad or
iPhone running i0S 9+, the camera can be used to scan
the VIN Barcode.
Please note ambient lighting, camera quality, etc. may
impact the effectiveness of the VIN scanning feature.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 31 of 35
TIP
After the VIN has been entered, the system will
automatically validate that it is a TDI VIN. This will be
indicated by a green check mark that will appear next to
the VIN.
•
Validate the VIN is correct for the vehicle, then click
the “Submit” button .
•
Select “Service Modification Documentation Form”
.
•
Follow the on-screen prompts completely.
NOTE
RISK of Non-payment!
Not using the IN-FORM tool to document and validate
the modification will stop the processing of payment for
your dealership even if the modification has been
completed.
TIP
Upon completion of the Service Modification
Documentation Form, the Manager must validate the
repair in the IN-FORM tool.
Proceed to Section I
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 32 of 35
Section I – Campaign Stamp
•
Once the campaign has been completed, the
technician should stamp the repair order.
•
Stamps are available for ordering through the
Compliance Label Ordering Portal (item#
AUD4927ENG or AUD4927FRE).
Proceed to Section J
Item#: AUD4927ENG
OR
Item # AUD4927FRE
Section J – Parts Return
Parts Return/Disposal
SCR Catalyst:
•
The SCR Catalyst must be tagged with a blue zip
tie  and returned in order to be
considered for core charge reimbursement.
All other parts:
•
Properly store (retain), destroy or dispose of
removed parts in accordance with all state and
local requirements, unless otherwise indicated
and/or requested through the Warranty Parts
Portal (WPP).
All Work Complete
Proceed to Section K for California Only
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 33 of 35
Section K – California Only Requirements
CALIFORNIA ONLY Requirements for Emissions Campaigns Having Customer Notification
The California Air Resources Board and the Department of Motor Vehicles (DMV) require emissions-related
campaigns to be completed prior to vehicle registration renewal. When campaign work is done you must provide
the owner with a signed “Vehicle Emission Recall – Proof of Correction” certificate (RC EMIS_CAL VW).
Certificates can be ordered at no cost online via the Compliance Label Ordering portal at www.accessaudi.com.
TIP
Ensure owners are aware of the importance of retaining the completed certificate for their records. It should be
mailed to the California DMV only upon request.
Appendix A – Warnings and Safety Precautions
WARNING
Note the following when working on the whole exhaust system:
•
Danger of eye injury, wear protective eyewear
•
Wear gloves (for example rubber gloves, not cloth gloves) and protective eyewear to prevent any harmful
contact with the skin and eyes - risk of injury.
•
Do not remove the exhaust gas temperature sensor - risk of injury.
WARNING
The reducing agent can cause skin irritation.
•
To prevent large amounts of reducing agent from leaking out when opening the metering line, wait for the
recirculation process to be completed.
•
Avoid contact with skin and eyes! Wear protective gloves!
•
If reducing agent should get on your skin, wash it off immediately with soap and water.
•
If reducing agent gets in your eye, rinse the eye for several minutes with water.
•
Never inhale or swallow the reducing agent!
•
Should you swallow any reducing agent, rinse your mouth, drink plenty of water and contact a doctor
immediately.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 34 of 35
Appendix B – 3.0L Gen 2.1 Parts Kit
Kit
4L0 298 099 X
Gen 2.1 Kit
Part Number
7P0 254 400 BX
7L5 253 115 C
1K0 253 141 J
N 91130802
N 01024713
4H0 131 113 A
3C0 253 725
059 906 261
Part Description
Exhaust Pipe With Catalyst And Adapters
Gasket
Dual Clamp
Shouldered Hex Nut
Replacement Stud/Bolt
Injector For Reduction Agent
Retaining Clamp
PM Sensor
Quantity
1
1
1
3
3
1
1
1
Diagram
Location
1
5
2
4
6
7
9
3 / 11
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2017 Audi of America, Inc. All Rights Reserved.
November 2017
23V5 Page 35 of 35