Exhaust System: Service and Repair

Exhaust system components, removing and installing

Note:
^ After work on the exhaust system ensure that the system is not under stress and that it has sufficient clearance from the bodywork. If necessary, loosen the double and single clamps and align the muffler and exhaust pipe so that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded.
^ Always replace self-locking nuts.





1. 25 Nm
2. Exhaust manifold
^ With turbocharger, Removing and Installing, Refer to Powertrain Mangement.
3. Gasket
^ Always replace
4. Heated Oxygen sensor (HO2S) -G39-, 50 Nm
^ Grease only the threads of sensor with G 052 112 A3
^ G 052 112 AS must not get into the slots on the sensor body
^ Remove and install with 3337
^ Checking: Refer to Powertrain Mangement.
5. Three Way Catalytic Converter (TWC)
^ Checking, Refer to Powertrain Mangement.
6. Oxygen sensor (02S) behind Three Way Catalytic Converter (TWC) -G130
^ Grease only the threads of sensor with G 052 112A3
^ G 052 112 AS must not get into the slots on the sensor body
^ Remove and install with 3337
^ Checking: Refer to Powertrain Mangement.
7. Mounting
^ With retaining ring
8. Mounting
9. 25 Nm
10. Rear muffler
^ As standard, center and rear mufflers are installed as a single component. For repairs, the mufflers are supplied individually and with a double clamp for connecting.
^ Removing and installing:
- Cut through connecting pipe separating point, item 16 at right angles with body saw, e.g. V.A.G 1523.
11. Dimension -a- approximately 7 to 9 mm
^ Exhaust system must be cold
^ Arrow points in direction of travel
12. Bolt head must face to fuel tank
13. Angle - a = 30 ± 5°
14. End of bolt must not be below double clamp
^ Double clamp as seen from normal direction of travel
15. Angle - B =10 + 5°
16. Separating point
^ Approximately 160 to 180 mm before the rear muffler, marked by a crimp in pipe.
17. Double clamp
^ Tighten evenly to 40 Nm
18. Center muffler
19. Double clamp
^ Tighten evenly to 40 Nm
20. Decoupling element
^ Max. misalignment = 10°
21. Mounting
^ Individual components see Fig. 1
22. Front exhaust pipe
23. 25 Nm
24. 30 Nm
25. Washer





Fig. 1 Individual mounting components

1. Buffer
2. Spacer pipe
3. Washer
4. Right-hand plate
5. Washer
6. Hex bolt
7. Spacer sleeve
8. Left-hand plate
9. Spring
10. Hex bolt
11. Self-locking nut, 25 Nm