Catalytic Converter: Service and Repair

LEGEND
1 Exhaust Manifold- 2-part
2 CO Tap Tube Nuts
3 CO Tap Tube- Where Applicable
4 Connector 4-Pin
5 Sealing Cap
6 Heated Oxygen Sensor (HO2S)
7 Nuts, 8 mm Or 10 mm
8 Double Clamp
9 Center Silencer
10 Mounting
11 Rear Silencer
12 Dimension -c- Approx. 10 mm (0.39 inch)
13 Marking For Double Clamp
14 Separation Point
15 Dimension -b- Approx. 5 mm (0.20 inch)
16 Marking Three Places On Circumference
17 Marking Three Places On Circumference
18 Dimension -a- Approx. 5 mm (0.20 inch)
19 Clamp
10 Support
21 Mounting
22 Lifting Eye
23 Front Silencer
24 Three Way Catalytic Converter (TWC)
25 Gasket
26 Front Exhaust Pipe
27 Gasket
28 Heat Shield

NOTE:
- During removal and installation procedures, refer to the component location illustration above and component notes below.
- After repairs be sure that the exhaust system is not under tension and that there is sufficient clearance between the exhaust system and the body.
- If necessary, loosen all clamps and align muffler and exhaust pipes for sufficient clearance and even load distribution at all mounting rings.
- Always replace self-locking nuts.

COMPONENT NOTES
CO Tap Tube Nuts (2)
- Tighten to: 25 Nm (18 ft. lbs.).

Connector 4-Pin (4)
- For H02S.
- Secured to right rear assembly mounting.

H2OS (6)
- Tighten to: 50 Nm (37 ft. lbs.).
- Apply anti-seize "G5", or equivalent, to threads only.
- Anti-seize must NOT get into slots on probe body.

Nuts, 8 mm Or 10 mm (7)
- Always replace.
- Tightening torques:
8 mm: 25 Nm (18 ft. lbs.).
10 mm: 40 Nm (30 ft. lbs.).

Dimension -c- (12)
- Approx. 10 mm (0.39 inch).

Marking (13)
- For double clamp.
- Three places on circumference.
- Distance from double clamp to marking - dimension -a-, item -18-.

Separation Point (14)
- For repair of individual parts.
- When replacing the center silencer item -9-.
- Three places on circumference of connecting pipe.
- In production center and rear silencers are one unit.
- For repair, center and rear silencers are supplied individually, with a double clamp for connection.
- Cut through connecting pipe at right angle to pipe, at separation point, using body saw, VAG 1523 or equivalent.

Dimension -b - (15)
- Approx. 5 mm (0.20 inch).

Marking (16)
- Three places on circumference.

Marking (17)
- Three places on circumference.
- "S" = Manual transmission.
- "A" = Automatic transmission.

Dimension -a- (18)
- Approx. 5 mm (0.20 inch).

Mounting (1)
- Note installation position.

Gasket (25)
- 2 piece.
- Always replace.

Gasket (27)
- 2 piece.
- Always replace.