Replacing the exhaust manifold (VW Golf 2)

The fastening of the exhaust manifold in the exhaust system is shown in Figure 264. To remove/install the elastic plate, a special device is required, the use of which is described below. If the operation concerns a turbocharged engine, it is necessary to familiarize yourself with chapter 5.13. During the work it is necessary to adhere to the following instructions:

• Always replace exhaust manifold gaskets.
• Always replace the gaskets between the manifold flange and the exhaust pipe.

The exhaust manifold is replaced as follows:

• Wait for the system to cool down.
• Gap between pins of special device 3049A (figure 265) align with the gaps between the holes in the spring plate. The direction of rotation for the purpose of compressing the plate is indicated by an arrow on the plate.

• Insert the pins of the device into the holes of the spring plate. The adjustable side of the device should be facing down, as shown in Figure 265. The arrow indicates the location where the spring plate should be. Insert the tee into the device and feed the device until it stops.
• By moving the intake pipe in the direction of the removed spring plate, remove the plate.
• Loosen the nuts and remove the exhaust manifold and its gaskets.

[The information is presented on the website: www.VWmanual.ru]



The exhaust manifold is installed in the reverse order, taking into account the following:

• Always replace the exhaust manifold gaskets and the gaskets between the manifold flange and the downpipe.
• During installation, the spring plate must be inserted into the cutout of the exhaust manifold, and then the 3049 tool must be compressed. Then the other end can be secured.
• Check that the plate is correctly installed in the cutout.
• When installing the intake pipe, secure the clamp loosely. Align all system elements and only then tighten the clamp nuts to a torque of 25 Nm.
• Tighten the nuts and bolts of all other components, as well as the bolts securing the exhaust pipe, to a torque of 25 Nm.
• Replace the rubber suspensions, paying attention to their design, as they are not all the same.
• When installing the rear muffler, check whether the rubber-metal ring is damaged. Tighten the fastening nuts to a torque of 25 Nm.
• After finishing work, start the engine and check at idle speed whether the exhaust system components are hitting the body structure components.

Figure 266 shows the middle and rear sections of the exhaust system. Replacing these units is not particularly difficult. Tighten the nuts and bolts of all clamps to 25 Nm.