Exhaust System: Service and Repair

Exhaust system components, removing and installing

Note:
^ Always replace seals, gaskets and self/Locking nuts.
^ Aft cable ties which are opened or cut open on removal must be replaced in same position when installing.
^ Any heat insulation sleeves which are taken off when removing must be re-attached in same position when installing.
^ After working on exhaust system ensure that system is not under stress, and that it has sufficient clearance from bodywork. If necessary, loosen clamps and align mufflers and exhaust pipes so that sufficient clearance is maintained to bodywork at aft points and mountings are evenly loaded.
^ Decoupling element in front exhaust pipe is never to be kinked by more than 10° otherwise it can be damaged.





1. Center muffler
^ Combined with rear muffler as original equipment; replace separately when performing repair work
^ Stress-free alignment of exhaust system; Alignment of exhaust system stress-free

2. 23 Nm
3. Mount
^ Replace if damaged
4. Heated Oxygen Sensor (H02S), 55 Nm
^ After catalytic converter
^ For cylinder bank 1 (right)
^ Grease thread only with hot bolt paste high-temperature lubricant G 052 112 A3; paste must not be allowed to come into contact with slits in probe body
5. 27 Nm
^ Always replace
^ Tighten evenly in several stages
6. Exhaust manifold
^ For cylinder bank 1 (right)
7. Gasket
^ Always replace
8. Heated Oxygen Sensor (HO2S), 55 Nm
^ Before catalytic converter
^ For cylinder bank 1 (right)
^ Grease thread only with high-temperature lubricant G 052 112 A3; paste must not be allowed to come into contact with slits in probe body
9. 27 Nm
^ Always replace
^ Tighten evenly in several stages
10. Exhaust manifold
^ Cylinder bank 2 (left)
11. Gasket
^ Always replace
12. Heated Oxygen Sensor (H02S), 55 Nm
^ Before catalytic converter
^ For cylinder bank 2 (left)
^ Grease thread only with high- temperature lubricant G 052 112 A3; paste must not be allowed to come into contact with slits in probe body
13. Front exhaust pipe with primary and main catalytic converter
^ For cylinder bank 2 (left)
^ With decoupling element
^ To avoid damage, decoupling element is never to be kinked by more than 10°
^ Protect against jolts and impact
^ Stress-free alignment of exhaust system; Alignment of exhaust system stress-free
14. Heated Oxygen Sensor (HO2S), 55 Nm Behind catalytic converter For cylinder bank 2 (left) Grease thread only with high- temperature lubricant G 052 112 A3; paste must not be allowed to come into contact with slits in probe body
15. Front clamp
^ Installation position; Refer to Fig. 1
^ Before tightening, perform stress-free alignment of exhaust system; Refer to Alignment of exhaust system stress-free
^ Tighten bolted joints evenly 16 -40 Nm
17. Front exhaust pipe with primary and main catalytic converter
^ For cylinder bank 1 (right)
^ With de-coupling element
^ To avoid damage, decoupling element is never to be kinked by more than 10°
^ Protect against jolts and impact
18. Rear muffler
19. Transverse strut
20. Bolt
21. Mount
^ Replace if damaged
22. 23 Nm
23. Rear muffler
24. 25 Nm
25. 40 Nm
26. Rear clamp





Fig. 1 Installation position of front clamps
- Install clamps so that the ends of bolts do not protrude beyond bottom edge of clamp.
^ Bolted joints face one another





Fig. 2 Installation position of rear clamps
- Install clamps so that the ends of bolts do not protrude beyond bottom edge of clamp.
^ Bolted joints face right





Fig. 3 Components of left mounting
1. Self-locking nut, 25 Nm
2. Bolt, 25 Nm
3. Heat shield for selector lever cable
4. Spacer sleeve
5. Buffer
6. Lug
7. Spacer sleeve
8. Support bracket
9. Bolt, 25 Nm
10. Washer
11. Spring
12. Spacer sleeve





Fig. 4 Components of right mounting
1. Washer
2. Lug
3. Buffer
4. Spacer sleeve
5. Bolt, 25 Nm
6. Bolt, 25 Nm
7. Washer
8. Spring
9. Spacer sleeve
10. Self-locking nut, 25 Nm

Center and rear muffler, separating
^ A cutting point is provided in the connecting pipe for separate replacement of center and rear muffler.
^ Cutting point is marked by an indentation on circumference of exhaust pipe.





Special tools and equipment
^ Body saw V.A.G. 1523 A
^ Safety goggles





- Separate exhaust pipe at right angles at cutting point (arrow) using body saw, e.g. VAG 1523 A.

WARNING: Use safety goggles.





^ On installation, center align clamps with saw cut.
- Install clamps so that the end of bolt (arrows) does not protrude beyond bottom edge of clamps; Refer to Fig. 2.
- Perform stress-free alignment of exhaust system; Refer to Alignment of exhaust system stress-free