Exhaust system maintenance (VW Golf 2)

1. The exhaust system must be checked after 15,000 km of mileage for leaks, damage and reliability of operation. To check the exhaust system, apply the handbrake, start the engine and let it idle. Check the exhaust system for leaks along its entire length, on both sides of the car, while an assistant briefly closes the exhaust pipe outlet with a folded rag. If the leak in any section is very large, it must be replaced with a new one. Check the condition of the rubber clamps and, if necessary, replace these elements with new ones (Fig. 3.55).



2. In models of cars with 1.6 and 1.8 engines, a hinged mount of the exhaust pipe to the exhaust manifold is used. The cuff of the exhaust pipe 5 is pressed against the cuff of the exhaust manifold using spring clamps 4 (figure 3.56).



To remove these clamps, the manufacturer provides a special tool, with which the clamp is bent to the length necessary for removal. As inconvenient as removing the clamp without this tool is, installation may also cause serious difficulties. Below are two ways to install the clamps.

Method 1

The clamp is stretched by successively driving in several wedges, increasing in height. The wedges must be made of 4 mm thick sheet metal with a not very large slope, so that after driving in the wedge does not move back. Therefore, the clamp must be stretched in several stages:

a) Place the clamp horizontally on the vice along the slightly spread jaws.

b) Drive in the first wedge.

c) Turn the clamp and drive in the next wedge, which is 4 mm larger than the previous one. The previous wedge falls out and a space is formed for driving in the next wedge. And so on until the clamp is not widened enough for installation.

Caution: Do not stretch the clamp beyond its limit, as it will lose its spring properties.

d) The same must be done with the second clamp.

d) After laying the wedges on the cuff, it is necessary to knock out the wedges.

Method 2

This method involves tying a steel wire to one side of a clamp. The clamp has two holes, one at each end.

a) A soft steel wire must be pulled through the window from the holes and its ends must be tied. A loop of 0.75 mm in length must be obtained.

b) Place the free end of the clamp on the exhaust manifold cuff and lower the wire down under the car.

c) The assistant must press the exhaust pipe cuff into the manifold socket.

d) Place a wooden beam or board across the car body.

d) Insert the steel tube into the wire loop and, like a lever, pull the wire down, resting the tube on a wooden beam pressed against the body. At this time, the assistant should push the clamp onto the exhaust pipe cuff. If the loop made at the beginning is very long, it is enough to twist the wire to shorten it.


4. Before performing any work on the exhaust system, wait until the system has cooled down, and then coat the mounting bolts and connections with a thin layer of rust remover.

5. When installing the exhaust system, you will need to install new bolts and nuts. It may be easier to cut the old bolts with a hacksaw than to remove them.

6. When removing any part of the exhaust system on models with 1.1 and 1.3L engines, it is usually easier to unscrew the bolts connecting the exhaust manifold and the front exhaust pipe and remove the entire system from the car, then separate it into individual parts or cut out the faulty parts with a hacksaw for metal.

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7. Assemble the system in sections, starting from the front.

8. Before installing the system, lubricate all its connections with an exhaust system sealant. This will ensure free movement of the parts relative to each other during mutual installation and ensure the tightness of the connections. Leave all bolts loose.

9. Start the engine and wait until the exhaust system reaches normal operating temperature. Then, with the engine idling, tighten all mounting bolts and clamps, starting from the exhaust manifold and moving towards the rear shock absorber. Avoid touching any part of the system with bare hands, as this can cause burns. Wear gloves when performing this work.

10. When tightening bolts and clamps, care must be taken to ensure that no part of the exhaust system is under tension.