Removal
Attention! All exhaust system parts can be replaced separately. In this case, you will need to disconnect the main and additional mufflers by cutting the connecting pipe along the marks on it with a pipe cutter.
Warning! Raising the vehicle with a jack and placing it on jack stands is dangerous. Please read the safety precautions in Chapter "Jacking up a car".
1. Place the vehicle on jack stands.
2. Remove the engine splash guard.
3. Treat all exhaust system mounting bolts and nuts with rust remover and let it work.
4. Cars with petrol engines. Disconnect the lambda probe connectors.
5. Vehicles with FSI petrol engine: Disconnect the connectors of the exhaust gas temperature sensor and the nitrogen oxide sensor, if present, then unscrew the bolts and remove the unit from these sensors.
6. Vehicles with 1.6L petrol engine BGU/BSE/BSF Remove the right drive shaft heat shield.
7. Disconnect the exhaust system cross support, if present.
8. Disconnect, acting in accordance with the engine type, the inlet pipe near the catalytic converter from the exhaust manifold or turbocharger.
9. Support the exhaust system or secure it with wire to the underbody so that it does not fall off after disconnection.
Caution! The flexible connection element of the inlet pipe must not be bent at an angle greater than 10°, because the element will be damaged in this case.
10. Remove the exhaust system, working with an assistant.
Attention! The exhaust system components can be removed individually. If the connecting elements or bolts do not separate or unscrew, heat the exhaust pipe at the joint with a burner, placing an aluminum sheet to protect the bottom.
Warning! Use caution. Fire hazard.
Installation
Attention! Replace seals, nuts and bolts with new ones without fail. To ensure that the exhaust pipe mounting nuts and bolts can be unscrewed without problems later, 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 of the exhaust pipe suspension and replace them with new ones if necessary.
If the pipes of the system are not being changed, then before connecting them, clean the mating surfaces with sandpaper, removing carbon deposits and remnants of sealing compound.
11. Connect the exhaust pipes. Tighten the mounting bolts by hand.
The connecting clamps must be installed so that the bolts on them are facing backwards or, when looking in the direction of travel of the vehicle, to the right.
12. Using the help of an assistant, secure the exhaust pipe to the suspension eyes and support it.
13. Secure the system with brackets or supports.
14. Connect the inlet pipe to the catalytic converter, to the exhaust manifold or turbocharger, installing a new sealing gasket.
15. Secure the pipe support bridge if it was removed. The tightening torque for the support bridge bolts is 35 Nm.
16. Vehicles with petrol engine BGU/BSE/BSF. Install the drive shaft heat shield. The tightening torque of the shield bolts is 35 Nm.
(The information is available on the website: www.vwmanual.ru)
17. Loosen the bolts of the connecting clamps and place the clamps at the joint as shown in the illustration. In this case, the lower edge of the bolt (see arrow in illustration) should not extend beyond the bottom edge of the clamp.
18. Straighten the exhaust system in the suspension elements so that its pipes are positioned without stress. In doing so, ensure that the pipes of the system are at least 25 mm away from the body. If necessary, shift the system in the longitudinal direction. The load on the suspension elements of the pipes must be the same. Make sure that the pipes at the joint are seated deep enough in the connecting clamps. Use the corresponding support notches on the pipes as a guide.
19. Tighten all bolts and nuts, see the corresponding illustrations for tightening torques.
The M8 bolts of the connecting clamps are tightened with a force of 25 Nm, and the M10 bolts - 40 Nm.
20. Cars with gasoline engines. Install the nitrogen oxide content and exhaust gas temperature sensor unit, if present and removed.
21. Replace the engine mudguard (protection).
22. Lower the car onto its wheels.
23. Check the exhaust system for leaks.
Some features of exhaust systems
24. Vehicles with 1.6 litre petrol engine BGU/BSF/BSE: Secure the downpipe to the exhaust manifold with new self-locking nuts to a tightening torque of 25 Nm (see illustration).
25. Vehicles with 2.0 litre (T)FSI engine and 1.6 litre petrol engine BGU/BSF/BSE. After aligning, move the exhaust pipes forward until the tension of the muffler suspension eye is a = 5-11 mm (see illustration).
Diesel Engine Cars
26. Position the connecting clamp so that the distance to the mark on the catalyst pipe is a = 5 mm (see illustration).
27. Push the muffler pipe into the connecting clamp so that the distance a is equal to 15-17 mm (see illustration).
28. Straighten the exhaust pipes so that they are horizontal.
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