Exhaust System: Service and Repair

Notes:
- After assembly work on the exhaust system, it is important to be careful that the exhaust system is not distorted and has adequate clearance to the bodywork. If necessary, loosen the double pipe clamps, collar bands, and exhaust pipe, and align them so that there is adequate clearance to the bodywork everywhere and the load is uniformly distributed on the hangers.
- The self-locking nuts must be replaced.
Special tools, equipment, test and inspection devices; required accessories:





- 3337 box wrench for oxygen sensor

Exhaust manifold/front exhaust pipe/catalytic converter with attachments





1. Seal
- Always replace
2. 25 Nm
3. Heat shield
4. Exhaust manifold
- Two-piece
5. Hanger shackle
6. 6 pin connector
- Black; for oxygen sensor and oxygen sensor heater
7. Oxygen sensor l preconverter -G39-, 50 Nm
- Grease only the thread with G 052 112 A. It may not touch slot on the sensor body
- Use wrenches 3337 to remove/install
8. 4 pin connector
- Black; for oxygen sensor and oxygen sensor heater
9. Oxygen sensor 2 post-converter G130-, 50 Nm
- In catalytic converter
- Grease only the thread with G 052 112 A3-it may not touch the slot on the sensor body
- Remove/install with box wrenches 3337
10. Front exhaust pipe with catalytic converter
11. To resonator
12. 10 Nm
13. 15 Nm
14. Heat shield
15. 40 Nm
16. Gasket for front exhaust pipe
- Always replace

Muffler with hangers

Note: Longitudinally, the exhaust system is to be aligned in such a way that the dimensions -a- and -b- are maintained.





1. From catalytic converter
2. Double pipe clamp
- Observe correct install position see Fig.3
3. 25 Nm
4. Hanger
- Observe correct install position see Fig. 4
5. Resonator
- Install resonator stress free see Fig. 2
6. Cutting line
- For repairs
- Marked by three indentations on the exhaust pipe
- It is standard to install resonator and rear muffler as one part. For repairs, the center and rear mufflers are delivered individually with a double pipe clamp for connecting.
- Use body saw, e.g. VAG 1523, to separate the connecting pipe perpendicular to the cutting line see Fig. 1
7. Hanger
8. Bracket
9. Rear muffler
10. Hanger
- With retaining ring
11. 20 Nm
12. Tubular bridge
13. 40 Nm
14. Washer





Fig. 1 Cutting line at exhaust pipe
- Separate exhaust pipe perpendicular to cutting line -arrow 2-.
- When installing, position new double pipe clamp -4- at lateral markings arrows 1 and 3-. Torque 40 Nm.





Fig. 2 Rear muffler - stress free installation
The bolts at exhaust pipe must be parallel to tubular bridge (dimension -x- same on left and right).





Fig. 3 Fitting position of the double pipe clamp
- Position double pipe clamp with about 5 mm clearance to marking -A-.

Note: The marking -A- applies both to vehicles with manual or automatic transmission.





Fig. 4 Fitting position of the hanger
The bent side at foot of hanger -arrow-points in direction of travel.