Catalytic Converter: Service and Repair

Front exhaust pipe and catalytic converter with attachments, assembly overview
1. From turbocharger
2. Seal
^ Replace
3. 25 Nm
^ Replace
4. Front exhaust pipe with catalytic converter
5. To muffler
6. Connector for mass air flow sensor-T6c-
7. Mounting
8. Heated Oxygen Sensor (H02S) G39-





Muffler with mountings
1. 40 Nm
2. From catalytic converter
3. Double clamp
4. 25 Nm
5. Mounting
6. Mounting
^ With retaining ring
7. Bracket
8. Mounting
9. Muffler
10. Separating point
11. 20 Nm
12. Tunnel bridge





Checking installation position of double clamp
- Position double clamp approximately 5 mm away from mark - A -
arrow -





Note: Mark - A - is valid for vehicles with manual and automatic transmissions.





Installed position of mounting
Angled side on foot of mounting - arrow - points forward.

Separating point on exhaust pipe
Special tools, testers and auxiliary items required
- Body repair saw e.g. V.A.G. 1523

Work sequence
- Separate exhaust pipe at right angles at separating point arrow 2-.





- Use repair type double clamp - 4 - at side markings - arrows 1 and 3 - when installing. Tightening torque- 40 Nm

Aligning rear muffler free of stress
The mounting pins on the exhaust pipe must run parallel with the tunnel bridge (dimension - x - is the same on left and right).