Exhaust System: Locations

Exhaust System Components, Removing And Installing

NOTE:
- 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 align exhaust pipe so that sufficient clearance is maintained to the bodywork and mounts carry uniform loads.
- Do not use any silicone sealant. Traces of silicone components which are sucked into the engine are not burned there, and they damage the oxygen sensor.
- Always replace self-locking nuts.
- Components marked with * are tested via On Board Diagnostic (OBD), Diagnostic mode 3: Check DTC memory.
- Check catalytic converter







1. 30 Nm
- Always replace
- Coat threads with G 052 112 A3
2. Exhaust manifold
- With turbocharger
3. Seal
- Always replace
4. Heated Oxygen Sensor (HO2S) -G39- bank 1*, 50 Nm
- Only use "G 052 112 A3" to grease thread; do not let "G 052 112 A3" get onto slit of oxygen sensor
- Check oxygen sensor heater for Oxygen Sensor (O2S) before Three Way Catalytic Converter (TWC)
- Check Oxygen Sensor (O2S) and oxygen sensor control before Three Way Catalytic Converter (TWC)
5. Catalytic converter
- Checking
6. Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- bank 1*, 50 Nm
- Only use "G 052 112 A3" to grease thread; do not let "G 052 112 A3" get onto slit of oxygen sensor
- Check oxygen sensor heater for Oxygen Sensor (O2S) behind Three Way Catalytic Converter (TWC)
- Check Oxygen Sensor (O2S) and oxygen sensor control behind Three Way Catalytic Converter (TWC)
7. 25 Nm
- Always replace
- Coat threads with G 052 112 A3
8. Marking
- 3x at perimeter
- Slide double clamp -item 21- up to marking on tube
9. Suspended mount
- With retainer ring
10. Suspended mount
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 body repair saw e.g. (VAG1523), cut at right angle through connecting pipe at separation point, item 18.
13. Dimension -a- = approx. 7 to 9 Nm
- 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 -alpha- = 30 ±5 degrees
16. Bolt end must not be below double clamp
- Double clamp viewed in direction of travel
17. Angle -Beta- = 10 +5 degrees
18. Separating point
- approx. 160 to 180 mm in front of rear muffler, marked by a 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
- max. flex 10 degrees
23. Suspended mount
- Individual components
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