Exhaust System: Service and Repair

EXHAUST SYSTEM, COMPONENT REPLACEMENT

NOTE: After working on the exhaust system ensure that the system (cold) is not pre-loaded. Check for sufficient clearance between the exhaust system and the chassis. If necessary, loosen the appropriate clamps to allow the mufflers and pipes to be turned and pushed in a longitudinal direction until sufficient clearance is obtained. The hanging load must be distributed equally over the entire set of retaining rings.

- Always replace the self-locking nuts.





a = approx. 5 mm
b = marking on pipe

1- Intake manifold

2- Gasket

3- EGR valve
- for California ONLY

4- 10 Nm (7 ft lb)
5- to the vacuum booster

6- Thermal Vacuum Valve (TVV)
- for California ONLY

7- Cap

8- CO tap tube

9- 30 Nm (22 ft lb)

10- 35 Nm (26ft lb)

11- 30 Nm (22 ft lb)

12- Oxygen sensor (02S)
- 50 Nm (44 ft lb)
- lubricate threads with G5 but do not allow G5 to enter the sensor slots

13- Front muffler
- note markings on pipe near the clamp
- S = manual trans.
- A = Automatic trans.

14- Dual clamp

15- 40 Nm (30 ft lb)

16- Catalytic convertor

17- 25Nm (18 ft lb)

18- Sealing ring

19- Front exhaust pipe
- to remove: loosen sub-frame, support on the right using engine and transmission jack VAG 1383A and remove the bolts on the right. Lower the sub-frame on the right by approx.10mm.

- tightening torques:
M12 = 130 Nm(96 ft lb)
M10 = 80 Nm(59 ft lb)

20- Heat shield

21 - Exhaust manifold

22- Intake air temperature sensor (G 72)
- 20 Nm (15 ft lb)
- for California ONLY
- function checked via On-Board Diagnosis