Removing and installing emission control module, LHD vehicles — VW

🧭 Before you start

Fits: VW Golf Cabriolet (517, 2011–2016); platform code 138

• Opens: coolant
• Special tools named: T10533
• Renewed: gaskets, any hose clips

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• The feet of assembly tool T10511 are supported on the bolt heads of the cylinder head cover.
• The position of the engine may have to be modified using the engine support T10533 to allow for removing the emission control module,and to avoid any collisions with components (e.g. ABS control unit).
• Clean all threads of compensation elements which do not move easily and moisten them with rust remover if necessary.
• Renew all securing bolts of the emission control module after removal.

🔧 Engine codes this applies to

📋 Procedure

1. Remove noise insulation General body repairs, exterior66Noise insulation; Assembly overview - noise insulation.
2. Remove subframe Running gear, axles, steering40Subframe; Removing and installing subframe with steering gear.
3. Remove front exhaust pipe .
4. Drain coolant .
5. Unscrew bolt (4) and turn filler neck for washer fluid reservoir (2) towards front.

6. Open clip (3) and pull connector (5) off coolant expansion tank (1).
7. Unscrew bolts (arrows), and lay coolant expansion tank (1) with coolant hoses connected to one side.
8. Remove coolant pipe (rear) .
9. Fit engine support T10533 as shown in illustration, and tighten bolts by hand. Bolt (1) is the original bolt for the pendulum support.
10. Push engine and gearbox as far as possible towards front by turning spindle on T10533. Avoid collisions between components and radiator cowl.
11. Remove exhaust gas recirculation cooler .
12. Remove exhaust gas temperature sender on emission control module .
13. Remove Lambda probe 1 before catalytic converterGX10.
14. Remove Lambda probe after catalytic converter G130.
15. Open heat insulation sleeve (1).
16. Remove connector (4) from retainer, release it, and pull it off.
17. Lay wire to one side.
18. Disconnect connectors (3 and 5) and lay wiring harness to one side.
19. Remove bolt (2) and move bracket with pressure differential sender G505 towards rear.
20. Remove bolt (arrow).
21. Open clip (A) and pull off hose. Unclip pipe (B) and remove it with pressure differential sender G505.
22. Open clip (A) and pull off hose. Unclip pipe (B) and remove it with pressure differential sender G505.
23. Open heat insulation sleeve (1).
24. Remove connector (5) from retainer, release it, and pull it off.
25. Lay wire to one side.
26. Disconnect connectors (3 and 4) and lay wiring harness to one side.
27. Remove bolt (2).
28. Remove bolt (3).
29. Release hose clips (1) and detach hoses.
30. Unclip pipe (2) and remove it together with pressure differential senders.
31. Remove bolt (arrow). [Note: The feet of assembly tool T10511 are supported on the bolt heads of the cylinder head cover.]
32. Fit assembly tool T10511 as shown.
33. Attach retaining bracket (arrow) in lifting shackle of emission control module.
34. Open clip (1) and position it on intake funnel of emission control module. [Note: The position of the engine may have to be modified using the engine support T10533 to allow for removing the emission control module,and to avoid any collisions with components (e.g. ABS control unit).]
35. Unscrew remaining bolts in sequence (4 ... 2).
36. Swing emission control module at bottom away from engine and push it upwards.
37. Pull retaining bar out of lifting shackle on emission control module and remove emission control module downwards. [Note: Ensure that the retaining bar of the assembly tool T10511 is »opened« towards plenum chamber bulkhead.Renew gaskets, self-locking nuts and screw-type clamp for emission control module after removal.Attach all cable ties and heat-shielding sleeves in the same places when installing.]
38. ⚠ Emission control module must be installed free of tension to avoid risk of stress fractures and engine damage.Ensure that the compensation elements move easily and that they are not seated too firmly.Compensation element must turn easily on its threads.Only lubricate the thread. The retainer tabs must remain »clean«.The retainer tabs for the bolt must be bent together so that when the bolt is screwed in, the compensation element is screwed in as well. — Check that compensation elements (arrow) are free to move.
39. Unscrew compensation elements completely by turning them in clockwise direction (left-hand thread).
40. Clean all threads of compensation elements which do not move easily and moisten them with rust remover if necessary.
41. ⚠ Ensure that no lubricant gets on the retainer tabs of the compensation elements. If the friction is reduced, functional impairment of the compensation elements will be the result. — Adapt retainer tabs to correct dimension using calibration tool T10512 as follows:
42. Slide compensation element onto shaft of calibration tool, and insert it into centring sleeve.
43. Bend the retainer tabs back with light blows on the ball head using your hand.
44. Screw in compensation elements completely by hand and then loosen them again by 45°.
45. Fit gasket (1) on emission control module.
46. Unhook bolt of clamp.
47. Place clamp (2) completely on intake funnel of emission control module.
48. Do not bend open clip.
49. Move emission control module to installation position from below, push it upwards and attach retaining bar in lifting shackle of emission control module. [Note: Renew all securing bolts of the emission control module after removal.]
50. Unscrew compensation element (left-hand thread) (1) on cylinder head in (direction of arrow) as far as stop using hexagon key extension, 8 mm3247. Then, turn it 90° further.
51. Install exhaust gas recirculation cooler .
52. Electrical connections and routing Electrical system97Relay carriers, fuse carriers, electronics boxes; Overview of fitting locations - relay carriers, fuse carriers, electronics boxes and .
53. Install left coolant pipes .
54. Install rear coolant pipe .
55. Install front exhaust pipe .
56. Renew any hose clips on pipes of emission control module.
57. Bolt pressure differential senders to cylinder head cover (6).
58. Install subframe Running gear, axles, steering40Subframe; Removing and installing subframe with steering rack.
59. Fit engine cover panel .
60. After renewing emission control module, perform Adaption in Guided Functions.

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