Emissions Control Module: Installing

WARNING: This page is about a different car, the 2015 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Place the Assembly Aid T10511 on the engine.

NOTE:

Pay attention that the Counterhold - Electric Drive T10511 retaining bracket is pivoted in the bulkhead direction - >>open<<.

Replace the seals, self -locking nuts, and clamps for the emissions control module after removing.

During installation, all cable ties for the heat shields must be installed at the same location.

CAUTION: There is a risk of stress fractures and engine damage due to the emissions control module being installed under stress.

Before installing make sure that this adjusting element is not difficult to move or tight.
The adjusting element must be easy to turn on the threads.
Lubricant can only be applied on the threads the connectors must remain >>clean<<.
The bolt connections must be bent together so far that the adjusting element is taken with then the bolt is turned.

-- Check and make sure that the adjusting element -arrow- turns easily.

Fig 1: Identifying Adjusting Element

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the adjusting element completely clockwise (left threads).

-- Clean difficult to move threads and is necessary coat with rust remover.

CAUTION: Adjusting element connections cannot be coated with every type of lubricant. Reducing the friction will influence the function of the adjusting element.

-- Bring the connections as follows with the Calibration Tool T10512 to the functional dimension.

-- Push the adjusting element on the striker pin and place in the centering sleeve.

Fig 2: Identifying Calibration Tool

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Bend back the connections with a light hit with the ball of the hand on the ball head.

-- Install the adjusting element by hand all the way in and loosen again to approximately 45°.

-- Install the seal -1- on the emissions control module.

-- Remove the clamp bolt.

Fig 3: Identifying Seal And Clamp

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place the clamp -2- completely on the emissions control module entrance funnel.

-- Do not bend the clamp.

-- Guide the emissions control module from below in the installed position, push upward and engage the bracket in the emissions control module mounting strap.

The emissions control module now hangs balanced in the approximate installation position.

NOTE: Replace all emissions control module bolts after removing.

Fig 4: Emissions Control Module Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Step	Bolt	Steps
I	Bolted clamp -1-	Position above the sealing flange and install the bolt.
II	Bolt -2-	Install hand tight and immediately loosen 90°
III	Bolted clamp -1-	Tighten to 8 Nm
IV	Bolt -2-	Tighten to 20 Nm
V	Bolt -3-	Install and pull to engage. Do not tighten or turn the bolt.
VI	Bolts -4-	Install and pull to engage. Tighten the bolts to 20 Nm.
VII	Bolt -3-	Tighten to 20 Nm

-- Remove the adjusting element (left threads) -1- on the cylinder head using the Hex Ball Socket 3247 in the direction of the -arrow- until stop, then tighten an additional 90°.

Fig 5: Identifying Adjusting Element

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Fig 6: Emissions Control Module Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Step	Bolt	Steps
VIII	Bolt -5-	Install and pull to engage.
IX	Bolt -5-	Tighten to 20 Nm
X	Bolt -5-	additional 90° turn.
XI	Bolt -5-	An additional 45° turn

The rest of the assembly is performed in reverse order of removal, noting the following:

-- After replacing the emissions control module, perform Adaptation in Guided Functions , refer to Vehicle Diagnostic Tester.