Emissions Recall

Emissions Recall
Code: 23V1
Subject
Release Date
Affected Vehicles
3.0L TDI Engine Emissions System Modification
July 26, 2018
U.S.A.:
2011-2012 MY Volkswagen Touareg 3.0L TDI Generation 1.2
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
3.0 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 July 26, 2018, affected vehicles will be listed on the Inventory Vehicle Open
Campaign Action report under My Dealership Reports. A list will not be posted for dealers who
do not have any affected vehicles. The campaign code will show open on affected vehicles in
Elsa and affected vehicles will be identified with this campaign code in the VIN Lookup tool at
www.vw.com.
Owner Notification
Owner letter examples are included in this bulletin for your reference. Owner notification will
take place on or about July 26, 2018.
Loaner/Rental Vehicle
– REQUIRED!
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.
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 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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 1 of 34
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 request via WISE under the Campaigns/Update/Recall Closure option.
Service Number
23V1
Damage Code
0099
Parts Vendor Code
Claim Type
Causal Indicator
Vehicle Wash/Loaner
Criteria I.D.
WWO
Sold vehicle: 7 10
Mark 3.0L Gen 1.2 Kit* as causal
Do not claim vehicle wash/loaner under this action
01
Install 3.0L Gen 1.2 Kit, install Glow Plug with Combustion Chamber Pressure Sensor,
install NOx Sensor (MY 2011), Top off AdBlue and ***Fuel tank, and **install a
supplemental Vehicle Emissions Control Information label and TDI Recall Proof of
Completion Label.
***Fuel must be claimed according to Warranty Circular VWP-17-16.
MY 2011:
Labor operation: 2360 25 99
Quantity
Part Number
7P0298099AX
059907807R
See ETKA
1
1
Up to 19.50L
MY 2012:
Labor operation: 2360 26 99
Quantity
Part Number
7P0298099AX
See ETKA
1
Up to 19.50L
255 T.U.
Description
3.0L Gen 1.2 Kit*
NOx Sensor
AdBlue
245 T.U.
Description
Gen 1.2 Kit
AdBlue
**Labels are sent free of charge. They cannot be charged to this campaign.
– LOANER/RENTAL MUST BE CLAIMED ON A SEPARATE LINE –
DO NOT PUT ON CAMPAIGN CLAIM
LOANER/RENTAL
Claim Type: A1A
Service #: CU01
Damage Code: 0010
Removed Part : MOB
Outside LO Number : CU010000
DO NOT PUT LOANER/RENTAL ON CAMPAIGN CLAIM
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 2 of 34
Campaign Work Procedure
23V1 Emissions Recall
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
Kit
Part Number
7P0 254 400 AX
7P0 298 099 AX
Gen 1.2 Kit
All vehicles
7L5 253 115 C
1K0 253 141 AF
N 911 308 02
N 010 247 13
4H0 131 113 A
3C0 253 725
059 905 061 H
059 907 807 R
See ETKA
N/A
Part Description
Exhaust Pipe With Catalyst And Adapters
(SCR Catalyst with Turbine Mixer)
Gasket
Dual Clamp
Shouldered Hex Nut
Replacement Stud/Bolt
Injector For Reduction Agent
(DEF Dosing Valve)
Retaining Clamp
Glow Plug with Combustion Chamber Pressure Sensor
(Cylinder Pressure Sensor)
NOx Sensor (MY 2011 ONLY)
AdBlue
Quantity
1
1
1
3
3
1
1
2
1
Up to 23.0L
Required Labels
Quantity
1
Part Description
TDI Recall Proof of Completion Label
1
TDI Recall Proof of Completion Label
1
VECI Label
1
VECI Label
Part Number
4L0 010 023 D
--OR-4L0 010 023 C
--AND-059 010 533 BA
--OR-059 010 533 BC
Vehicle
MY 2011 Touareg
MY 2012 Touareg
MY 2011 Touareg
MY 2012 Touareg
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 3 of 34
Required Tools
VAS6150X - Diagnostic
Tester (or equivalent)
VAS6154 - Vehicle
Communication
Interface (or equivalent)
GRX3000VAS – Battery
Tester/Charger (or
equivalent)
Glow Plug Socket
– VAS6454
Torque Wrench 1331
5-50Nm -VAG 1331
Ring Wrench 7-Piece
Set -3337-
Torque Wrench 1332 40200Nm -VAG 1332
Torque Wrench 1331
5-50Nm -VAG 1331
Engine Bung Set
-VAS6122-
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 4 of 34

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.
Repair 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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 5 of 34
Section B – Repair Procedure
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 6 of 34
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 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 do not impose a concern,
continue the work procedure.
NOTE
If there are pre-existing conditions such as damage to
the intake, exhaust and emissions systems or
modifications from original equipment or MIL is
illuminated, address these issues prior to this repair.
This work is NOT covered by this campaign.

Check for illumination of the MIL .
o If MIL is not illuminated, continue the work
procedure.
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 7 of 34
Section D – Refill AdBlue

Lift the rear compartment carpet <1> and slide it
back.

If equipped remove the spare tire <2> by removing
the wing nut <3>.

If equipped remove the foam piece <3>.
WARNING

Protect the hands when prying the plug out of
the tank filler neck.

Sharp-edged body components could cause
injury.

Remove the plug from the fuel tank filler neck <1>.

Open the AdBlue filler cap <1> and fill the tank.
Part Number
See ETKA

Description
AdBlue
Quantity
Up to 19.5L
You will later be required to perform the Reducing
Agent Injector -N474- adaption using Vehicle
Diagnostic Tester - Guided Functions. You will be
prompted to do this after the Flash procedure.
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 8 of 34
Section E – 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 3 mph.
If equipped with air suspension:

Switch the ignition on.

Switch the electrical parking brake on.

Press the
seconds.
o
LOCK
button in the center console for 5
The Vehicle Lift Mode is displayed in the
Instrument cluster and the indicator lamp
in the LOCK button flashes when vehicle
is ready to lift.

Turn off the ignition.

Carefully pull the engine cover off the bolts one
after the other in direction of . Do not
pull sharply on the engine cover or pull it to one
side.
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 9 of 34

Disconnect the glow plug connector <1> from
Cylinder 2 and Cylinder 5 Glow Plug with
Combustion Chamber Pressure Sensors (G678)
<2>.

Clean the glow plug ducts 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 a 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 and Cylinder 5 Glow Plug
with Combustion Chamber Pressure Sensors
(G678) <2> using Glow Plug Socket – VAS6454.

Carefully remove the Cylinder 2 and Cylinder 5
Glow Plug with Combustion Chamber Pressure
Sensors (G678) by hand or with a hose without
bending it.

Carefully install new Cylinder 2 and Cylinder 5
Glow Plug with Combustion Chamber Pressure
Sensors (G678) <2> by hand or with a hose
without bending them.
Part Number
059905061H
Description
Quantity
Glow Plug with
Combustion Chamber
Pressure Sensor
2

Using Glow Plug Socket - VAS6454, tighten to 12
Nm.

Reconnect the glow plug connectors <1> from
Cylinder 2 Glow Plug with Combustion Chamber
Pressure Sensors (G678) <2> and make sure
they are 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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 10 of 34

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.
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 .
Figure 
NOx Module location.
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 11 of 34

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
time.
This will reduce the possibility of
contaminating the electrical connection with
AdBlue.

Secure the Reducing Agent Injector out of the way
with a tie strap (or equivalent).

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.
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 12 of 34

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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 13 of 34
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.

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

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
Lubricate the OTC 5057 clevis/stud press
tool threads and the press pin contact tip
with hot bolt paste or anti-sieze lubricant
before each use.
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.
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 14 of 34
MY 2011 ONLY:

Loosen the mounting elements  and
move the heat shield to the left.
MY 2011 ONLY:

Disconnect the electrical connector <1> from the
NOx Sensor Control Module 2 -J881-.

Remove the nuts  and remove the NOx
Sensor Control Module 2 -J881- and NOx Sensor
2 -G687- as an assembly.
MY 2011 ONLY:

Install new NOx sensor Control Module 2 -J881and tighten the nuts  to 3.5 Nm.

Connect the electrical connector <1>.
Part Number
059 907 807 R
Description
Quantity
NOx Sensor
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 15 of 34

Reinstall the heat shield and tighten the mounting
elements .
Continue for All MY vehicles

Install the new (MY 2011) or original (MY 2012)
NOx Sensor 2 -G687- <1> and tighten to 50 Nm.
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 AF
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 16 of 34

Install the new Reducing Agent Injector -N474<5> ensuring that the tabs in the Injector fit
properly into the corresponding mounts in the
SCR catalytic converter <2> (electric connector
faces up).
Part Number
4H0 131 113 A
Description
Quantity
Injector For Reduction
Agent
1
TIP
The gasket <4> comes pre-installed on the new
Injector.

Install a new retaining clamp <3> and tighten bolt
to 5 Nm.
Part Number
3C0 253 725
Description
Quantity
Retaining Clamp
1

Reconnect the connector <1>.

Reinstall the reducing agent hose <6> ensuring
the clasps are secure.
NOTE


The adaptation value in the Engine Control
Module (ECM) must be adapted with the
Vehicle Diagnostic Tester when the reducing
agent injector is replaced.

Perform the adaption using Vehicle Diagnostic
Tester - Guided Functions once all the
required components have been replaced.
Install the new exhaust clamping sleeve 
but leave the nuts loose.
Part Number
1K0 253 141 AF
Description
Quantity
Dual 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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 17 of 34

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 in the
sub-photo. Pull 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 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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 18 of 34
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.

Figure 
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.
Hold the exhaust system in this position and
tighten the clamping sleeve screws evenly to 23
Nm.
NOTE
If all adjustment dimensions are not achieved, remove
affected bracket from body and shift accordingly.
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 19 of 34

Align the tailpipes by first loosening the screwtype clamp  on the tail pipes.

Adjust the tailpipes to the specifications below.

o
Dimension  = 20 mm minimum.
o
Dimension  = align evenly.
Tighten the screw-type clamps  to 60 Nm.
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 20 of 34
Section F – 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 or WiFi 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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 21 of 34
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 22 of 34

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.

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.

Open the hood.

Open the battery cover.

Attach the GRX3000VAS Tester/Charger (or
equivalent) to the vehicle battery jump point and
ground jump point.
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.
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 23 of 34

Confirm that scan tool is communicating with the
diagnostic head by USB .


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.
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.

Once the GFF scan is complete, select “Special
functions”.

Select the test plan “Adapt software, diesel,
exhaust EA189 action 23XX” .

Select “Perform test” .
NOTE
RISK of Improper Repair!
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 24 of 34


DO NOT SELECT the normal test plan for
“Adapting Software”.

ONLY SELECT the test plan “Adapt software,
diesel, exhaust EA189 action 23XX” to
perform this repair.
Select “Complete/Continue”  after the
control module adaptation, action 23XX note
appears.
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.

Enter the corrective action code (SVM code) as
listed below.
SVM code
4065

Select “Accept” .

Select “Complete/Continue”  to begin the
software update process.
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 25 of 34

Observe flash process and follow any on-screen
prompts to complete the test plan.
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.

When the SVM update is complete a confirmation
message is displayed .

Select “Complete/Continue” .

Switch
the
ignition
off,
“Complete/Continue” .
then
select
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 26 of 34

The green check mark indicates the test plan was
successfully carried out.
NOTE
In the event of a Flash Malfunction!
In the event of a flash error or malfunction, STOP. DO
NOT exit the scan tool, attempt the flash again, or
continue further in the test plan. Create a VTA ticket and
allow the VW Technicians Helpline to provide direction
with flash failures.

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.
TIP
When exiting GFF, it is important to select “No”
.
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 27 of 34
TIP
It is possible after the flash that the TPMS light may be
illuminated. Follow test plan “03 – Tire pressure
monitoring display” .

If TPMS light illuminates, follow test plan “03 – Tire
pressure monitoring display” by selecting
“Perform test” .

Disconnect the VAS tester.

Switch off and disconnect the battery charger.

Reinstall the battery cover.

Release the parking brake.

Perform test drive.
Proceed to Section G
Section G – 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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 28 of 34

Open the hood.

Clean the surface where the label is to be
installed .

Install the supplemental Vehicle Emissions
Control Information (VECI) label 059 010 533 BA
or 059 010 533 BC (based on vehicle model year)
according to the chart below, onto the underside
of the hood or onto the core support as shown.
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.

Be certain the correct model year sticker is
placed on the correct model year vehicle.
Vehicle
Label part number
MY 2011
059 010 533 BA
MY 2012
059 010 533 BC
NOTE
DO NOT Cover ANY existing labels!
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 29 of 34
Section H – TDI Emissions Modification – Proof of Completion Label
Install TDI Emissions Modification 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 where 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 part
number 7P0 010 023 D or 7P0 010 023 C (based
on vehicle model year) 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.

Be certain the correct model year sticker is placed
on the correct model year vehicle.
Vehicle
Label part number
MY 2011
7P0 010 023 D
MY 2012
7P0 010 023 C
NOTE
DO NOT Cover ANY existing labels!

Apply clear overlay (provided).

Close the hood.
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 30 of 34
Section I – Service Modification Documentation Requirements
Job Roles Summary:





Service Consultant – Initiates validation tool.
Service Technician – Completes service
modification requirements.
Manager – Validates the modification was properly
completed.
Cashier – Prints receipt, fuel economy label and
delivers to customer.
Warranty Administrator – Enters claim into the
SAGA system.
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 31 of 34
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 J
Section J – Parts Return
Parts Return/Disposal
Properly store (retain), destroy or dispose of removed parts
in accordance with all state/province and local
requirements, unless otherwise indicated and/or requested
through the Warranty Parts Portal (WPP) for U.S. and
SAGA for Canada.
All Work Complete
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 32 of 34
Appendix A – Warnings and Safety Precautions
WARNING

Danger of eye injury, wear protective eyewear.
WARNING
Note the following when working on the whole exhaust system:

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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 33 of 34
Appendix B – 3.0L Gen 1.2 Parts Kit
Kit
7P0 298 099 AX
Gen 1.2 Kit
All vehicles
Part Number
4L0 254 400 AX
7L5 253 115 C
1K0 253 141 AF
N 911 308 02
N 010 247 13
4H0 131 113 A
3C0 253 725
059 905 061 H
Part Description
Exhaust Pipe With Catalyst And Adapters
Gasket
Dual Clamp
Shouldered Hex Nut
Replacement Stud/Bolt
Injector For Reduction Agent
Retaining Clamp
Glow Plug with Combustion Chamber Pressure Sensor
Quantity
1
1
1
3
3
1
1
2
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. 2018 Volkswagen Group of America, Inc. All Rights Reserved.
July 2018
23V1 Page 34 of 34