VW Touareg V10 TDI DPF Removal

(performed on 2007MY , 2006MY/2008MY may vary slightly)

OFFROAD USE ONLY, REMOVING DPF IS NOT LEGAL IN MANY STATES AND WILL FAIL EMISSIONS TESTS

Tools Needed:
Vehicle Lift; Assorted Wrenches; Bendable Wrenches; Air Ratchet/Wrench
Clamp Removal Tool ; Hose Removal Tool; Hand Chisel/hammer and/or Air Chisel (much easier)

You may need to use the following tools, so be prepared to have access to them:
-Transmission Jack; Cutting Torch; Welder, Tapping Tool, Extraction Sockets

Supplies Needed:
-Nothing major, maybe a few hose clamps and a rubber hose if needed. Some heat shrink tubing
all new bolts/nuts for exhaust components

Procedure

1. Flash ECU with DPF Delete File, Verify vehicle runs and clear any trans errors with code tool
(Malone Tuning sells the DPF delete ECU service)
2. With vehicle up on lift, remove plastic skid plates from underside where you will be working.
3. Locate DPF’s Canisters.
4. Start by removing the mounting bolts that hold the brackets to the canisters/car.
5. Remove 2 temp sensors from each DPF, but do not cut wires. You will most likely need to heat
up the dpf’s to get the sensors unscrewed. If you cannot remove them , or destroy them trying
to remove them (they can cross thread when backing them out) , then just make sure they are
sealed (if you get them in a “loose” position and cannot tighten them, weld the open area
between the sensor cable and the metal sensor, so as to not have any place for gasses to
escape). If you cannot get the sensors unscrewed, it is OK to cut the wires. Just put heat shrink
over the wires coming from the vehicle, as they are very had to unplug (the plug is up above the
transmission)
6. Remove hose from 2 pressure sensors on each canister. You may need some hose clamps if you
ruin the snap clamps.
7. Loosen the 2 bolts on each clamp that hold the DPF pipe to the exhaust piping on either side.
Work the clamps off both side, and slide the “sleeve” back along the exhaust pipe towards the
rear of the vehicle. Make sure you do not line up the “slices” in the sleeve; they should be offset
to prevent an exhaust leak.
8. Start removing the 3 nuts/bolts on the DPF flange that attach to the flexible tubing coming from
the oxidation cat. Careful not to twist or bend the flexible tubing too much. These like most of
the bolts on your exhaust system will most likely be rusted, and may break when removing
 them. Use some heat to try and remove them without breaking the bolts off. If needed, use a
cutting torch VERY carefully, to remove the nuts, or what is left of them. Use extreme caution to
not burn the mesh around the flexible exhaust hose, as it will melt easily, and is extremely
difficult and expensive to fix. Use a piece of aluminum or other metal in between where you are
cutting and the hose to prevent damage when cutting. When you get all 3 bolts off, try gently
tapping or prying in between the flanges to get them to break free. Use caution not to damage
the metal gasket.
9. The passenger side DPF proves much more difficult to remove, especially if you need to cut the
bolts. For this, you will need to use a transmission jack , and support the transmission. Then
remove the bolts holding the transmission support bearing to the transmission, and then
transmission support bar to the chassis. Remove the support bar, and place aside. This will allow
you to bend the DPF downward and get better access to the top bolts on it. Again, be careful
when cutting not to damage the flexible hose.
10. Now the fun part? With the DPF’s removed, use an air powered chisel or a hand chisel and
hammer, and start to break the DPF material inside each DPF, just keep chiseling away at it until
it breaks into small enough pieces to shake out of the opening. Chisel some, and then shake the
material out, and repeat. There is also a cotton material that needs to be removed from the
inside. You will also find 2 metal mesh bands in each DPF that must be pulled out from the
inside. There is one on either end of the DPF. Blow the DPF’s clean with air, and make sure
everything is removed from them.
11. Now, using all new hardware/bolts, replace the DPF’s back in the vehicle, first putting the
supporting bolts back in, then the flange bolts, connection sleeves, screw sensors back in,
tighten.
12. Start the vehicle and check for exhaust leaks, and fix as needed.
13. Enjoy the MPG increase and some black smoke!