Muffler: Service and Repair

Mufflers With Mounts

1 From Three Way Catalytic Converter (TWC)
2 Marking
3 Carriage bolts
4 Double clamp
- replace
- Note installed position see Fig. 1
5 M8 -25 Nm M10 -40 Nm
6 Suspended mount
- Note installed position see Fig. 3
7 Front muffler
- At factory, front and rear mufflers are installed as a single component. Replacement front and rear mufflers are supplied separately, with replacement double clamp for connecting joint.
- Install front muffler parallel see Fig. 2
- Separating point see Fig. 4
- Adjusting exhaust system.
8 Suspended mount
9 Rear muffler
- At factory, front and rear mufflers are installed as a single component. Replacement front and rear mufflers are supplied separately, with replacement double clamp for connecting joint.
- Separating point see Fig. 4
- Note installed position of end pipes see Fig. 5
10 Suspended mount
11 Tunnel bridge
- with hole for alignment of exhaust system
- Aligning exhaust system

Fig. 1 Installation position of double clamp

Procedure
- Position new double clamp as shown with approx. 5 mm distance to marking -A-and tighten it.
Tightening torque 40 Nm

NOTE: Marking -A-is valid for vehicles with manual and automatic transmission.

Fig. 2 Aligning front muffler parallel

Procedure
- Mounting bolt at exhaust pipe must be parallel to tunnel bridge (dimension -x-same at left and right).

Fig. 3 Installation position of muffler suspension

Procedure
- Angled side at foot of suspension (arrow) faces front of vehicle.

Fig. 4 Separation point at exhaust pipe

Recommended special tools and equipment
- Body saw, e.g. VAG1523

Procedure
- Separate exhaust pipe at right angle to separation point (arrow 2).
- Position replacement double clamp -4- in installation position at the edge markings (arrows 1 and 3) as shown when installing.
Tightening torque 40 Nm

Fig. 5 Installed position of end pipes of rear muffler

Procedure
- Align rear muffler so that dimensions -x-and -y-of end pipes -1- are equal at left and right to body.