Exhaust System Components, Removing and Installing (Front Wheel Drive Vehicles)

Exhaust System Components, Removing And Installing (Front Wheel Drive Vehicles)







1. Turbocharger
2. Gasket
- Always replace
3. Heated Oxygen Sensor (HO2S) -G39-, 50 Nm
- Black connector
- Grease threads only with hot bolt paste G 052 112 A3; paste must not be allowed to come into contact with slits in sensor body
4. Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-, 50 Nm
- Brown connector
- Grease threads only with hot bolt paste G 052 112 A3; paste must not be allowed to come into contact with slits in sensor body
5. Catalytic converter
- Protect from impact damage
6. Gasket
- Replace
7. 25 Nm
8. Front exhaust pipe
- With decoupling element
- To avoid damage, do not bend decoupling element by more than 10 degrees
9. Front clamp
- Align exhaust system so it is free of stress before tightening clamp
- Installed position of bolt ends, see Fig. 1.
- Tighten bolted connections evenly
10. 40 Nm
11. Spacer sleeve
12. Buffer
13. Lug
14. Washer
15. M10 bolt, 30 Nm
16. Mounting
17. 25 Nm
18. Rear muffler (left)
- Tailpipe can be replaced
- Rear muffler and center muffler are one unit as original equipment but can be replaced separately for repair purposes.
- Cutting point.
- Stress-free alignment of exhaust system
- Replacing tailpipe, see Fig. 3
19. Rear muffler (right)
- Tailpipe can be replaced
- Rear muffler and center muffler are one unit as original equipment but can be replaced separately for repair purposes.
- Cutting point.
- Stress-free alignment of exhaust system
- Replacing tailpipe, see Fig. 3
20. Rear clamps
- For separate replacement of center muffler and both rear mufflers
- Align exhaust system so it is free of stress before tightening clamp
- Installed position, see Fig. 2.
- Tighten bolted connections evenly
21. 40 Nm
22. Center muffler
- Center muffler and both rear mufflers are one unit as original equipment but can be replaced separately for repair purposes.
- Cutting point.
- Stress-free alignment of exhaust system
23. 25 Nm
24. Mounting
25. 25 Nm
26. Mounting
27. M8 bolt
28. Washer
29. Spring
30. Lug
31. Spacer sleeve
32. 25 Nm
33. 40 Nm







Fig. 1 Installed position of front clamp

- Install clamp so that ends of bolts are not below bottom circumference of clamp.
- Bolted connection on left







Fig. 2 Installed position of rear clamps

- Install clamps so that ends of bolts are not below bottom circumference of clamps.
- Bolted connections on outside
- Align exhaust system stress-free
- Tighten bolted connections evenly to 40 Nm.







Fig. 3 Replacing tailpipe

- Cut through tailpipe -1- squarely at cutting point -C- using body saw, e.g. VAG 1523A.
- Push on tailpipe -3- up to marking -A-. When doing so, make sure that slot in tailpipe is in line with marking -B-.
- Tighten bolted connection on clamp -2- to 25 Nm.