Cars with a gasoline engine have two lambda probes, one of which is installed in front of the additional catalyst, and the second - after the additional catalyst.
Diesel vehicles have only one catalytic converter (see illustrations 1.0, 1.0a, 1.0b, 1.0c, 1.0d, 1.0e).
In the event of a repair, all parts of the exhaust system can be replaced individually.
Attention! The secondary and main mufflers are serially produced as a single unit. However, you can change them individually. To do this, the connecting pipe must be cut at the marked location. When installing, the pipe of the new muffler is connected using a pipe clamp, the bolts of which are tightened with a force of 25 Nm.
On vehicles with a BLF engine, only the second lambda probe is installed with a tightening torque of 50 Nm.
Operation of vehicles with a catalyst
To avoid damage to the lambda probe and catalyst, the following recommendations must be strictly followed:
Gasoline engines
Refuel with unleaded gasoline only.
It is not recommended to perform a forced start of the engine with a push or towing. If necessary, only one attempt is allowed at a distance of not more than 50 meters. In this case, it is best to use an auxiliary battery. Unburned fuel, if ignited, can cause overheating and destruction of the catalyst. If the engine is warm, then forced start from a push or towing is generally unacceptable.
If misfires are observed, high engine speeds must be avoided and the fault repaired immediately.
Install only the types of spark plugs recommended by the vehicle manufacturer.
Do not perform spark tests with the spark plug tip removed.
Do not compare cylinders (balance test) by turning off the ignition in the combustion chamber of one cylinder. With such a shutdown, including with the help of an engine test stand, unburned fuel enters the catalyst.
Vehicles with petrol and diesel engines
Do not park your vehicle over dry leaves or grass. The exhaust system in the area of the catalytic converter is very hot and emits heat even after the engine has been switched off.
Do not apply underbody corrosion protection to parts of the exhaust system.
Do not modify the heat shields of the exhaust system.
If the engine is difficult to start, do not operate the starter for too long. When starting the engine, fuel is continuously injected. In such cases, you need to find and eliminate the cause of the malfunction.
Keep an eye on the amount of fuel in the tank and do not let it «devastation».
When refueling and adding engine oil, pay special attention to ensure that the maximum oil level mark on the dipstick is not exceeded. Excess oil due to incomplete combustion enters the catalyst and can damage the precious metal or completely destroy the catalyst.
Catalyst design
The catalyst is designed to reduce the level of harmful substances in the exhaust gases.
It consists of a ceramic monolith 2 with a honeycomb structure, covered with a protective layer (see illustration 1.0g). On the protective layer there are salts of noble metals, which provide the process of cleaning the exhaust gas.
In the case 1 of the catalyst is a support insulator 3, which compensates for thermal expansion.
1.0. Details of the exhaust system. Vehicles with 1.4 liter BCA petrol engine
1 - heat reflective shield
2 - bolts. Tightening torque 10 Nm
3 - exhaust manifold
4 - sealing gasket. To be replaced with a new one after each dismantling
5 - nut. Tightening torque 25 Nm. To be replaced with a new one after each dismantling
6 - nut. Tightening torque 40 Nm. To be replaced with a new one after each dismantling
7 - clamping clamp. Bolt tightening torque 25 Nm. Before tightening the bolts of the pipes of the exhaust system, align them and install without tension. Tighten bolts/nuts evenly
8 - to the additional muffler
9 - support
10 - main catalyst
11 - nut. Tightening torque 23 Nm
12 - second lambda probe. Tightening torque 55 Nm. The probe thread should be lubricated with protective paste G052112AZ. The paste must not get into the slot of the lambda probe
13 - connecting plug of the second lambda probe. Located on the right side under the protection of the bottom
14 - nut. Tightening torque 25 Nm
15 - connecting plug of the first lambda probe
16 - the first lambda probe. Tightening torque 55 Nm. This lambda probe is located in front of the additional catalyst. The probe thread should be lubricated with protective paste G052112A3. The paste must not get into the slot of the lambda probe
17 - additional catalyst with a downpipe. Depending on the model, it can be attached with an additional bracket
18 - wire harness guide
19 - bolt. Tightening torque 25 Nm
20 - downpipe suspension
1.0a. Details of the exhaust system. Vehicles with 1.4 liter BCA petrol engine
1 - bolt. Tightening torque 25 Nm
2 - rubber suspension ring. Check for damage
3 - the place of the pipe cut. Marked with notches
4 - main muffler
5 - suspension bracket. If damaged, replace with a new one
6 - bolt and nut for fastening the support jumper. Tightening torque 23 Nm
7- support jumper
8 - additional muffler
9 - suspension bracket. Observe installation position
1.0b. Details of the exhaust system. Vehicles with 1.4-/1.6-litre FSI petrol engine
1 - heat reflective shield
2 - bolts. Tightening torque 10 Nm
3 - exhaust manifold
4 - sealing gasket. To be replaced with a new one after each dismantling
5 - nut. Tightening torque 25 Nm. To be replaced with a new one after each dismantling
6 - nut. Tightening torque 40 Nm. To be replaced with a new one after each dismantling
7 - spacer B - bracket
9 - nut. Tightening torque 60 Nm
10 - bolt. Tightening torque 25 Nm
11 - suspension of the receiving pipe
12 - bolt. Tightening torque 25 Nm
13 - clamping collar
14 - to the additional muffler
15 - main catalyst with a downpipe
16 - a block consisting of a nitrogen oxide content sensor and a second lambda probe (vehicles with BKG/BLN/BAG/BLP engine). The tightening torque of the lambda probe is 50 Nm. The probe thread should be lubricated with protective paste G052112A3. The paste must not get into the slot of the lambda probe
17 - nut
18 - nut. Tightening torque 25 Nm
19 - connecting plug of the first lambda probe
20 - the first lambda probe. Tightening torque 50 Nm. This lambda probe is located in front of the additional catalyst. The probe thread should be lubricated with protective paste G052112A3. The paste must not get into the slot of the lambda probe
21 - connector for exhaust gas temperature sensor
22 - exhaust gas temperature sensor. Tightening torque 45 Nm. Not available for BLF engines. For vehicles with a BLN/BLP engine, it is screwed in front of the main catalyst, not near the auxiliary one
23 - additional catalyst with a downpipe. For vehicles with a BLN/BLF/BLP engine, it is attached with an additional bracket with a tightening torque of 40 Nm
24 - generator wiring harness guide
25 - corrugated cover
1.0v. Details of the exhaust system. Vehicles with 1.4-/1.6-litre FSI petrol engine
1 - rubber suspension ring. Replace if damaged
2 - bolts. Tightening torque 25 Nm
3 - bracket. Observe installation position
4 - additional muffler
5 - bolt. Tightening torque 25 Nm
6 - bracket. Observe installation position
7 - suspension. Replace if damaged
8 - main muffler
9 - rubber suspension ring. Replace if damaged
1.0g Details of the exhaust system. Vehicles with 2.0 liter FSI petrol engine
1 - nut. Tightening torque 25 Nm. If damaged, it must be replaced. Exhaust manifold pin threads should be lubricated with heat resistant paste
2 - second lambda probe (vehicles with AXW/BLR/BLX engine) Tightening torque 55 Nm. This lambda probe is located behind the catalyst. Black probe connector. The probe thread should be lubricated with protective paste G052112A3. The paste must not get into the slot of the lambda probe
3 - second lambda probe (vehicles with AXW/BLR/BIX engine). Tightening torque 55 Nm. This lambda probe is located behind the catalyst. Probe connector brown. The probe thread should be lubricated with protective paste G052112A3. The paste must not get into the slot of the lambda probe.
4 - exhaust gas temperature sensor for vehicles with AXW/BLX engine. Tightening torque 45 Nm. BLY engines have a lambda probe. Tightening torque 55 Nm. Probe connector brown. The probe thread should be lubricated with protective paste G052112A3. The paste must not get into the slot of the lambda probe.
5 - storage catalyst for nitrogen oxides in cars with an AXW / BLX engine. For BLR/BLY engines, there is a conventional catalytic converter here, mounted on a downpipe with a connecting element. It is not allowed to bend the connecting element of the downpipe at an angle of more than 10', because in this case it will be damaged.
6 - nitrogen oxide content sensor (vehicles with AXW/BLX engine). Sensor tightening torque 60 Nm. The sensor thread should be lubricated with protective paste G052112A3. For BLR/BLY engines, there is a third lambda probe behind the catalytic converter. Probe tightening torque 55Nm. The sensor thread should be lubricated with protective paste G052112A3. The paste must not get into the slot of the lambda probe.
7 - suspension ring. To be replaced if damaged
8 - nut. Tightening torque 25 Nm
9 - suspension ring. To be replaced if damaged
10 - muffler. Attention! The secondary and main mufflers are serially produced as a single unit. However, you can change them individually.
11 - suspension bracket. To be replaced if damaged
12 - bolt. Tightening torque 25 Nm
13 - clamping collar. Required to connect the pipes of the additional and main mufflers when replacing one of them. Clamp bolts should be tightened evenly
14 - main muffler. Additional and main mufflers are serially produced as a single unit
15 - suspension ring. To be replaced if damaged
16 - bolts. Tightening torque 25 Nm
17 - clamping collar
18 - nut. Tightening torque 25 Nm
19 - suspension bracket
20 - bolt. Tightening torque 25 Nm
21 - suspension bracket. To be replaced if damaged
22 - sealing gasket. To be replaced after each disassembly
1.0d. Details of the exhaust system. Vehicles with 4-valve 1.9-/2.0-liter diesel engine
1 - downpipe with catalyst
2 - suspension bracket. To be replaced if damaged
3 - bolt. Tightening torque 25 Nm
4 - clamping collar
5 - nut. Tightening torque 25 Nm
6 - suspension ring of the additional muffler To be replaced if damaged
7 - suspension ring of the main muffler. To be replaced if damaged
8 - additional and main mufflers. In case of replacement, they can be installed separately
9 - suspension bracket with ring
10 - the place of the pipe cut. Marked with notches
11 - bolt. Tightening torque 25 Nm
12 - suspension ring. To be replaced if damaged
13 - suspension bracket
14 - bolt. Tightening torque 40 Nm
15 - bolt. Tightening torque 40 Nm
16 - support jumper
17 - seal. To be replaced after each disassembly. Observe installation position
18 - collar
19 - clamp bolt. Tightening torque 7 Nm
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