Procedures

Exhaust System Components, Removing And Installing

NOTE:
- Always replace seals and gaskets, self-locking nuts and clamps.
- After working on the exhaust system ensure that the system is not under stress, and that it has sufficient clearance from the bodywork. If necessary, loosen clamp and align silencers and exhaust pipe so that sufficient clearance is maintained to the bodywork at all points and the mounts are evenly loaded.
- Loosen and tighten clamping plates for heat shields with a screwdriver. Tightening torque: 2 Nm
- De-coupling element on front exhaust pipe may only be bent slightly - not more than 10 degrees.
- If droning noises can be heard after aligning the exhaust system, adjust the engine mounts.







1 - 40 Nm
- Always replace
2 - Oxygen sensor, 55 Nm
- Apply "G5" lubricant only on the threads; "G5" must not come into contact with the slots on the body of the Oxygen sensor
- Checking:
3 - Mounting
- Secured on subframe
4 - 25 Nm
5 - Catalytic converter
6 - Mounting
7 - 25 Nm
8 - Front and rear silencers
- Can be replaced separately if required
- Exhaust pipe with cutting point => Fig.1
- Aligning exhaust system free of stress
9 - 25 Nm
10 - Mounting
11 - 25 Nm
12 - 25 Nm
13 - Clamp
- Align exhaust system so it is free of stress before tightening clamp.
- Installation position: horizontal in vehicle, bolted connection facing to the left.
- Tighten bolted connections evenly.
14 - Tunnel cross-piece
- With drilling for aligning exhaust system
15 - Gasket
- Always replace
16 - 25 Nm
17 - Front exhaust pipe
- With de-coupling element
- Protect from damage by knocks and impact
- De-coupling element may only be bent slightly - not more than 10 degrees







Fig. 1 Marked position for cutting exhaust pipe

- For separate replacement of front or rear silencer
- Position is marked with three indentations on exhaust pipe.

- Cut through exhaust pipe at right angles with body saw (e.g. V.A.G 1523) at position marked (arrow -2-).
- Position clamp -4- between side markings (arrows 1 and 3) when installing.
- Aligning exhaust system free of stress.
- Align rear silencer so it is horizontal.
- Tighten bolted connections on clamp evenly to 40 Nm.
- Installation position of clamp - horizontal in vehicle; bolted connections facing to the front.







Fig. 2 Clearance between exhaust pipe and heat shield for steering gear: not less than 30 mm

- To check this clearance, install a 22 mm 1/2-inch socket (outside diameter approx. 30 mm) on a long extension and insert between front exhaust pipe and heat shield. The socket attachment must fit easily in the gap.







Fig. 3 Align catalytic converter horizontally -4- and with equal spacing -3- from heat shield in center tunnel -2-. Item -1- is the drive shaft.

- Align front and rear silencers centrally and horizontally. If necessary, detach tunnel cross piece.