Right Exhaust Pipe W/Converter, Removing and Installing
Right Exhaust Pipe With Catalytic Converter, Removing And Installing
NOTE: Next, removal and installation for vehicles with automatic transmission is described.
Special tools and equipment
- V.A.G 1383 A engine/transmission hoist
- 3337 wrench, 7-piece set
- Hot bolt paste G 052 112 A3
Removing
- Remove rear engine cover (arrows).
- Remove cover -1- in engine compartment (right side).
- Remove bolts (arrows).
- Remove air guide -1-.
- Detach Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- (-1-) at air filter housing.
- Remove air filter housing (arrows).
- Remove bolts for holding plate -3- for solenoid valves (arrows).
- Disconnect intake air hose -1- at Mass Air Flow (MAF) sensor.
- Remove hose -4- from air duct -2-.
- Remove bolt (arrow) and disconnect air duct -2- at throttle valve control module.
- Disconnect hose -1- from air duct.
NOTE: Illustration depicts air guide from rear with the engine removed.
- Remove harness connectors -1- to -4- from bracket at right of bulkhead.
- Disconnect electrical harness connectors -1- and -4-.
- Guide wires to the oxygen sensors downward.
Vehicles with automatic transmission 01J:
- Unscrew oxygen sensor behind catalytic converter (arrow) using special tool 3337.
All:
- Remove nut -2- which is accessible from top for exhaust pipe/exhaust manifold.
NOTE: Illustration is shown with engine removed.
- Remove right front wheel
- For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater on noise insulation.
- Loosen mounting parts -1- to -4- and remove noise insulation.
- Remove heat shield -1- for right drive axle.
NOTE: Decoupling element in front exhaust pipe must not be bent more than 10 degree, otherwise it may be damaged.
- Disconnect exhaust system at right double clamp (right arrow).
- Remove heat shield above exhaust system.
- Remove heat shield for drive shaft -arrows-.
- Remove bolts at flange of transmission/drive shaft.
- Push driveshaft to rear final drive together. The constant velocity joints can be adjusted axially.
- Rest driveshaft on exhaust system.
- Remove VAG1359/2 universal mount from VAG1383A engine/gearbox jack and place a piece of wood -1- onto punch instead.
- Support transmission using VAG1383A engine/transmission jack.
NOTE: For automatic transmission 01 V, position engine/transmission lift directly behind the ATF pan. Insert a wood block to protect the transmission housing. Never lift at the ATF pan.
CAUTION: The lock carrier must be installed.
- First remove bolts -2- and -3- and then mounting bolts -1- and -4- of subframe.
- Slowly lower transmission and subframe using VAG1383A engine/gearbox jack.
- Remove bracket for front exhaust pipe (arrow).
- Slightly lift transmission and installed piece of wood using VAG1383A engine/transmission jack.
- Remove bolts -1- to -4- for transmission mounts.
- Unbolt both transmission supports -5- and -6- at transmission housing and remove transmission supports with transmission mounts.
- Slowly lower transmission again.
- Expose oxygen sensor wires.
- Remove nuts -1- and -3- which are accessible from bottom for front exhaust pipe/exhaust manifold.
NOTE: Illustration is shown with engine removed.
- Remove front exhaust pipe with catalytic converter.
Installing
Installation is the reverse of removal, noting the following:
NOTE:
- All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
- Replace gaskets and self-locking nuts.
- Install transmission mounts and supports.
- Install subframe.
- Installing driveshaft.
- Install exhaust system free of stress.
NOTE: Individual mounting components for exhaust system to transmission on vehicles with Front Wheel Drive (FWD), See Fig. 3 up to Fig. 6.
Fig. 3 Individual left mounting components for vehicles with manual transmission
1 Bolt (25 Nm)
2 Spacer sleeve
3 Strap
4 Buffer
5 Washer
6 Bolt (25 Nm)
7 Washer
8 Compression spring
9 Spacer sleeve
10 Self-locking nut (25 Nm)
Fig. 4 Individual right mounting components for vehicles with manual transmission
1 Self-locking nut (25 Nm)
2 Washer
3 Washer
4 Buffer
5 Spacer sleeve
6 Washer
7 Washer
8 Bolt (25 Nm)
9 Spacer sleeve
10 Strap
11 Strap
12 Compression spring
13 Washer
14 Bolt (25 Nm)
Fig. 5 Individual left mounting components for vehicles with automatic transmission 01J
1 Self-locking nut (25 Nm)
2 Washer
3 Bracket
4 Strap
5 Buffer
6 Spacer sleeve
7 Bolt (25 Nm)
8 Bolt (25 Nm)
9 Washer
10 Compression spring
11 Bolt (25 Nm)
12 Spacer sleeve
13 Self-locking nut (25 Nm)
Fig. 6 Individual right mounting components for vehicles with automatic transmission 01J
1 Spacer sleeve
2 Strap
3 Buffer
4 Spacer sleeve
5 Bolt (25 Nm)
6 Bolt (25 Nm)
7 Washer
8 Compression spring
9 Spacer sleeve
10 Washer
11 Self-locking nut (25 Nm)
NOTE: Individual mounting components for exhaust system to transmission on vehicles with All Wheel Drive (AWD), See Fig. 3 up to Fig. 6.
Fig. 3 Individual left mounting components for vehicles with manual transmission
1 Self-locking nut (25 Nm)
2 Washer
3 Spacer sleeve
4 Strap
5 Buffer
6 Washer
7 Bolt (25 Nm)
8 Spacer sleeve
9 Compression spring
10 Washer
11 Bolt (25 Nm)
Fig. 4 Individual right mounting components for vehicles with manual transmission
1 Bolt (25 Nm)
2 Washer
3 Buffer
4 Strap
5 Spacer sleeve
6 Washer
7 Self-locking nut (25 Nm)
8 Bolt (25 Nm)
9 Washer
10 Compression spring
11 Spacer sleeve
Fig. 5 Individual left mounting components for vehicles with automatic transmission 01V
1 Self-locking nut (25 Nm)
2 Bolt (25 Nm)
3 Heat shield for selector lever cable
4 Spacer sleeve
5 Buffer
6 Strap
7 Spacer sleeve
8 Bracket
9 Bolt (25 Nm)
10 Washer
11 Compression spring
12 Spacer sleeve
Fig. 6 Individual right mounting components for vehicles with automatic transmission 01V
1 Washer
2 Strap
3 Buffer
4 Spacer sleeve
5 Bolt (25 Nm)
6 Bolt (25 Nm)
7 Washer
8 Compression spring
9 Spacer sleeve
10 Self-locking nut (25 Nm)
- The threads of new oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body.
- When re-using the old oxygen sensor, grease the threads with hot bolt paste; the paste must not get into slots of oxygen sensor body.
- Wires of oxygen sensors must always be secured in the same position when installing so that contact with the exhaust pipe is avoided.
Tightening Torques
Component Nm
Front exhaust pipe with catalytic converter to exhaust manifold 27
Front exhaust pipe with catalytic converter to mounting strap 25
Drive axle protection to transmission 23
Oxygen sensor to catalytic converter 55