Removing
Attention! All parts of the exhaust system can be replaced individually. In this case, it will be necessary to separate the main and additional mufflers by cutting the connecting pipe along the marks made on it with a pipe cutter.
Attention! Jacking up the vehicle and placing it on jack stands are dangerous. Please read the safety precautions in chapter «car jacking».
1. Place the vehicle on jack stands.
2. Remove the engine mudguard.
3. Treat all bolts and nuts of the exhaust system with a rust remover and let it work.
4. Cars with a gasoline engine. Disconnect the lambda probes.
5. Vehicles with FSI petrol engine. Disconnect, if any, the plugs of the exhaust gas temperature sensor and the nitrogen oxide content sensor, and then unscrew the bolts and remove the block from these sensors.
6. Vehicles with 1.6 liter BGU/BSE/BSF petrol engines. Remove the right drive shaft heat shield.
7. Disconnect if there is a transverse bearing of the exhaust system.
8. Disconnect, according to the type of engine, the exhaust pipe near the catalyst, from the exhaust manifold or turbocharger.
9. Support the exhaust system or secure it to the bottom with a wire so that it does not fall after disconnection.
Attention! The flexible connecting element of the downpipe must not be bent at an angle of more than 10°, because the element is then damaged.
10. Remove the exhaust system, working together with an assistant.
Attention! The parts of the exhaust system can be removed individually. If the connectors or bolts do not separate or unscrew, heat the exhaust pipe at the joint with a burner, laying an aluminum sheet to protect the bottom.
Attention! Be careful. Fire hazard.
Installation
Attention! Seals, nuts and bolts must be replaced with new ones without fail. So that the nuts and bolts of the exhaust pipe can later be unscrewed without problems, it is recommended to lubricate them with a protective paste that is resistant to high temperatures, such as Liqui Moly-3080. Check the condition of the rubber rings for the exhaust pipes and, if necessary, replace them with new ones.
If the pipes of the system do not change, then before connecting them, clean the mating surfaces with a sandpaper, removing carbon deposits and remnants of the sealing mass.
11. Connect the exhaust pipes. Tighten the mounting bolts by hand.
The connecting collars must be installed so that the bolts on them are turned to the rear or, if you look in the direction of the vehicle, to the right.
12. Fasten the exhaust pipe, working together with an assistant, in the suspension lugs and support it.
13. Secure the system with brackets or supports.
14. Connect downpipe to catalytic converter, exhaust manifold or turbocharger with new gasket.
15. Attach the pipe support bridge, if removed. The tightening torque for the support head bolts is 35 Nm.
16. Vehicles with BGU/BSE/BSF petrol engines. Install the driveshaft heat shield. The tightening torque for the shield bolts is 35 Nm.
17. Loosen the bolts of the connecting clamps and seat the clamps at the junction as shown in the illustration. In this case, the lower edge of the bolt (see arrow in illustration) must not extend beyond the lower edge of the collar.
18. Straighten the exhaust system in the suspension elements so that its pipes are located without stress. When doing this, make sure that the pipes of the system are at least 25 mm from the body. If necessary, move the system longitudinally. The load on the pipe suspension elements must be the same. Make sure that the pipes at the joint are set deep enough in the connecting clamps. Guided by the corresponding support notches on the pipes.
19. Tighten all bolts and nuts, see relevant illustrations for tightening torques.
The M8 bolts of the connecting clamps are tightened with a force of 25 Nm, and the M10 bolts with 40 Nm.
20. Cars with a gasoline engine. Reinstall, if present and removed, the block of sensors for the content of nitrogen oxides and exhaust gas temperature.
21. Replace the mudguard (protection) engine.
22. Lower the car on wheels.
23. Check the tightness of the exhaust system.
Some features of exhaust systems
24. Vehicles with 1.6 liter BGU/BSF/BSE petrol engines. Fasten the exhaust pipe to the exhaust manifold with new self-locking nuts with a tightening torque of 25 Nm (see illustration).
25. Cars with an engine (T) 2.0 liter FSI and 1.6 liter BGU/BSF/BSE petrol engine. Move the pipes of the exhaust system after their alignment forward so that the tension of the muffler suspension eye is a = 5-11 mm (see illustration).
Diesel vehicles
26. Position the connecting clamp so that the distance to the mark on the catalyst pipe is a = 5 mm (see illustration).
27. Slide the muffler pipe into the connecting clamp so that the distance a is 15-17 mm (see illustration).
28. Straighten the pipes of the exhaust system so that they are horizontal.
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