Removal and installation of the exhaust system (VW Passat B3)

Removal

Raise the car.

Spray all bolts and nuts of the exhaust system with rust remover. Leave the product on the surfaces of the parts for a while to show its effect.

Remove the subsequent muffler.

Unscrew the protective screen.

Cars before 9/93

Remove the hold-down springs between the exhaust manifold and the front exhaust pipe.

Note: This requires the spring removal device VAG 3049A or HAZET2585. This is easiest to do with a special device with a spacer wedge VAG 3140/2 or HAZET 2586-3. Never remove springs without these devices.

Removal using a spring remover

The distance between the pins of the device should be adjusted to the distance between the holes of the pressure springs.



Insert the spring remover into the spring holes and loosen it slightly by hand. To do this, turn the knurled washer in the direction of the arrow on the VAG device (arrow on the end of a knurled washer).

Insert the T-handle into the spring release tool and stretch the spring until it stops.



Remove the pressure spring from the recesses of the outlet pipe and outlet tube by pressing the outlet tube in the direction of the pressure spring being removed.

Remove the second spring in the same way.

Removal using a wedge tool

Press the exhaust pipe to the side. This will stretch the spring located on the side where the exhaust pipe is pressed. In this position, insert the short expansion wedge VAG 3140/2 or HAZET 2586-3 into the pressure spring. Stretch the second pressure spring in the same way and insert the expansion wedge.

Note: If there is a dual exhaust pipe, insert the pry bar "A" between the pipes to stretch the spring, or if there is a single pipe, grasp it with a pipe wrench and press the pipe to the side. If necessary, remove the exhaust system from the retaining tracks.

Press the front exhaust pipe in the direction of the pressure spring, which should be removed first. Check the strength of the pressure spring grip with a spacer wedge, remove the spring.

Support the exhaust system from the front with a garage jack (or ask an assistant to support her) and remove the retaining rings both in the middle and at the back.


Remove the exhaust system.

The exhaust system parts can be removed separately. If the connecting sections or bolts do not unscrew, heat the exhaust pipe at the connection point with a welding torch. Put asbestos under it!

Warning: Fire hazard!

Caution, 16-valve engines up to 9/92: If the front exhaust pipe is to be removed, first loosen the front axle beam, support it on the right with the VAG 1383 device or a garage jack with a suitable gasket and unscrew the bolts on the right. Lower the front axle beam on the right by about 10 mm. After installation, tighten the beam mounting bolts to the body to the following torques: M12 bolts - 130 Nm, M10 bolts - 80 Nm.

Installation

Note: Rubber rings, nuts and bolts must be replaced. In order to make it easier to loosen the exhaust system nuts and bolts later, it is recommended to lubricate them with a high-temperature paste, such as Liqui Moly LM-508-ASC.

Connect the front exhaust pipe and the pre-silencer and tighten the clamp slightly. If necessary, clean the connecting element of the clamp from carbon deposits with sandpaper before tightening.

The end seal between the exhaust pipe and the front exhaust pipe should only be replaced if damaged or leaking and should be removed using a screwdriver.

Insert the trunnions of the spring removal device into the holes of the pressure spring. Use the device to loosen and insert the spring, first inserting the spring into the recess on the side of the outlet pipe.

Loosen the spring remover and insert it into the second spring. Finally, check that the springs are correctly installed in the recesses. If spacer wedges are used, insert the stretched pressure springs and ensure that their ends enter the recesses of the front exhaust pipe and the exhaust pipe. Remove the spacer wedges by pressing the front exhaust pipe to the side.

Install the next muffler, do not tighten the clamps yet.

Before tightening the bolts, align the exhaust system. Make sure there is sufficient distance to the body (not less than 25 mm), otherwise, turn the exhaust system or move it in the longitudinal direction. The retaining rings must be loaded evenly. Make sure that the pipes enter the clamps far enough, the distance "a" from the marking on the pipe to the clamp should be approximately 5 mm, see large picture.



16-valve engines and all models from 10/93: When aligning the exhaust system, ensure that the rear suspension of the subsequent silencer protrudes from the rubber bracket by a distance of b = 10 mm. If necessary, move the pre-silencer in the clamping sleeve.

Tighten the bolts and nuts. Tightening torques for bolts depend on the thread diameter: M6 bolts — 5 Nm, M8 bolts — 25 Nm, M10 bolts — 40 Nm.

Screw on the heat shield with new self-locking nuts.

Lower the car, see section "Lifting a car".

Sequence of fastening the exhaust pipe to the exhaust manifold