Exhaust System: Service and Repair

Exhaust system components, removing and installing

WARNING! Observe the following for all installations, especially in engine compartment due to lack of room:
^ Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
^ Watch for sufficient clearance to all moving or hot components.

Notes:
^ After exhaust system repairs, make sure exhaust system is not under stress and that it has sufficient clearance from the bodywork. If necessary, loosen double clamps and clamp and align exhaust pipe so that sufficient clearance is maintained to the bodywork and support rings carry uniform loads.
^ Always replace self-locking nuts.





1- 30 Nm
^ Always replace
^ Coat threads with G 052 112 A3
2- Exhaust manifold
^ with turbocharger, Refer to Powertrain Management.
3- Gasket
^ Always replace
4- Heated Oxygen Sensor (H02S) - G39 before catalytic converter, 50 Nm
^ Only use "G 052 112A3" to grease thread; do not let G 052 112 A3 get onto slit of oxygen sensor
^ use 3337 to remove and install
^ Checking:
Refer to Powertrain Management
5- Catalytic converter
^ Checking, Refer to Powertrain Management.
6- Oxygen Sensor (02S)
^ Behind Three Way Catalytic Converter (TWC) - G130-
^ Only use "G 052 112 A3" to grease thread; do not let "G 052 112 A3" get onto slit of oxygen sensor
^ use 3337 to remove and install
^ Checking:
Refer to Powertrain Management.
7- 25 Nm
^ Always replace
^ Coat threads with G 052 112A3
8- Marking
^ 3x at perimeter
^ Slide double clamp - item no. 21 -up to marking on tube
9- Support ring
^ With retainer ring
10- Support ring
11- 25 Nm
12- Rear muffler
^ At factory, center and rear mufflers are installed as a single component. Replacement center and rear mufflers are supplied separately, with double clamp for connecting joint.
^ Removing and installing:
- Using VAG1523 chassis saw, cut at right angle through connecting pipe at separation point - 18
13- Dimension -a- = approximately 7 to 9 mm
^ Exhaust system must be cold
^ Arrow shows direction of travel
^ To adjust exhaust system, slide double clamp - 21 - onto exhaust pipe up to marking - 8 - and tighten slightly Slide center and rear mufflers far enough forward that dimension -a- is obtained. Tighten double clamp.
14- Bolt head must face fuel tank
15- Angle - = 30 ± 5°
16- Bolt end must not be below double clamp
^ Double clamp viewed in direction of travel
17 - Angle - = 10 ± 5
18- Separating - point
^ approximately 160 to 180 mm in front of rear muffler, marked bye recess in the pipe.
19- Double clamp
^ Tighten evenly to 40 Nm
20 - Center muffler
21- Double clamp
^ Tighten evenly to 40 Nm
22- Decoupling - element maximum flex 10°
23- Support ring
^ Individual components see Fig. 1
24- Front exhaust pipe
25- 30 Nm
^ Always replace
^ Coat threads with G 052 112 A3
26- Washer





Fig. 1 Individual components of suspension
1- Strap with buffer
2- Exhaust pipe
3- Washer
4- Hex bolt, 25 Nm
5- Self-locking nut, 25 Nm
6- Spacer sleeve
7- Compression spring
8- Hex bolt