Front Wheel Drive (FWD) Vehicles

Front Wheel Drive (FWD) vehicles







1 Tunnel bridge
- with hole for alignment of exhaust system
2 Suspended mount
- Installation position See Fig. 2
3 25 Nm
4 Front exhaust pipe
- with catalytic converter
- Check catalytic converter
- with decoupling element
- Protect from hit- and impact stress
- do not over-bend flex pipe, max. flex 10 degree
- Distance between exhaust pipe and heat shield See Fig. 3
5 40 Nm
- replace
6 Spacer sleeve
- for all four nuts
7 Seal
- replace
8 Turbocharger
9 Heated Oxygen Sensor (HO2S) -G39-* before catalytic converter, 50 Nm
- Use "G5" to grease thread only; do not let "G5" get onto slits of oxygen sensor body
- Harness connector for oxygen sensor under protective cover
- Check Oxygen Sensor (O2S) and oxygen sensor control before Three Way Catalytic Converter (TWC)
- Check oxygen sensor heater for Oxygen Sensor (O2S) before Three Way Catalytic Converter (TWC)
10 Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-*, 50 Nm
- Use "G5" to grease thread only; do not let "G5" get onto slits of oxygen sensor body
- Harness connector for oxygen sensor under protective cover
- Check Oxygen Sensor (O2S) and oxygen sensor control behind Three Way Catalytic Converter (TWC)
- Check oxygen sensor heater for Oxygen Sensor (O2S) behind Three Way Catalytic Converter (TWC)
11 Clamping sleeve
- Before tightening, ensure exhaust system is tension-free
- Installation position: Horizontally in vehicle, bolt points to the left
- Tighten bolts evenly
12 40 Nm
13 Suspended mount
14 25 Nm
15 Front and rear muffler
- If repair is necessary, replace separately
- Exhaust pipe with separation point See Fig. 1
16 Suspended mount
17 25 Nm
18 25 Nm

Fig. 1 Separating point







- for individual replacement of front or rear muffler
- marked by three depressions around the circumference of the exhaust pipe.

- Using body repair saw, e.g. VAG1523, cut exhaust pipe at separating point (arrow 2) at right angle.
- Position clamping sleeve -4- at the edge markings (arrows 1 and 3) when installing.
- Align rear muffler horizontally.
- Tighten double clamp bolts evenly to 40 Nm.
- Double clamp installed position Horizontally in vehicle, bolts point to the front


Fig. 2 Installation position for suspended mount (Vehicles with Front Wheel Drive)







Angled side (arrow) at foot of suspended mount faces front of vehicle.

Fig. 3 Distance between exhaust pipe and heat shield for steering gear at least 24 mm







- To measure distance, connect 17 mm 1/2-inch socket insert (diameter approx. 24 mm) to a long extension and slide it between front pipe and shielding plate. Socket wrench insert should easily slide in between.