Exhaust system device (VW Passat B5)

Exhaust system of front-wheel drive vehicles with four- and five-cylinder petrol engines

Warning: The illustration shows the exhaust system of a vehicle with a 1.8-I ADR engine.

• 1 - nut, 25 Nm,
• 2 - exhaust manifold,
• 3 - oxygen sensor, 50 Nm,
• 4 - gasket,
• 5 - exhaust inlet pipe,
• 6 - nut, 30 Nm,
• 7 - nut, 25 Nm,
• 8 - catalyst,
• 9 - clamp,
• 10 - pillow,
• 11 - bolt, 25 Nm,
• 12 - additional muffler,
• 13 - size A = 7–9 mm,
• 14 - exhaust pipe connection point,
• 15 - central muffler,
• 16 - clamping bracket, 40 Nm,
• 17 - exhaust pipe connection point,
• 18 - central muffler,
• 19 - suspension,
• 20 - exhaust inlet pipe,
• 21 - catalyst,
• 22 - washer

Exhaust system of front-wheel drive vehicles with diesel engine

• 1 - additional muffler,
• 2 - central muffler,
• 3 - suspension,
• 4 - bolt, 25 Nm,
• 5 - suspension,
• 6 - clamping bracket, 40 Nm,
• 7 - intermediate pipe,
• 8 - nut, 25 Nm,
• 9 - turbocharger,
• 10 - gasket,
• 11 - catalyst,
• 12 - bolt, 25 Nm,
• 13 - gasket,
• 14 - nut, 25 Nm

Exhaust manifolds and exhaust pipes for cars with 6V engines (the rest of the exhaust system is the same as in all-wheel drive vehicles)

• 1 - bushing,
• 2 - bolt,
• 3 - washer,
• 4 - bracket,
• 5 - bushing,
• 6 - rubber bushing,
• 7 - nut, 25 Nm,
• 8 - spring,
• 9 - bolt, 25 Nm,
• 10 - to the central part of the exhaust system,
• 11 - left exhaust pipe with catalytic converter,
• 12 - oxygen sensor No.2, 50 Nm,
• 13 - black four-pin electrical connector,
• 14 - nut, 25 Nm,
• 15 - cap, 10 Nm,
• 16 - branch pipe,
• 17 - upper heat shield,
• 18 - lower heat shield,
• 19 - left exhaust manifold,
• 20 - gasket,
• 21 - right exhaust manifold,
• 22 - oxygen sensor No.1, 50 Nm,
• 23 - right inlet pipe with catalytic converter

Central and rear exhaust system on all-wheel drive vehicles with four- and five-cylinder engines

• 1 - bolt, 25 Nm,
• 2 - suspension,
• 3 - nut, 40 Nm,
• 4 - screw with a semicircular head,
• 5 - clamping bracket, 40 Nm,
• 6 - place of connection of pipes of the exhaust system,
• 7 - right additional muffler,
• 8 - suspension,
• 9 - bracket,
• 10 - left additional muffler,
• 11 - intermediate exhaust pipe,
• 12 - gasket,
• 13 - catalyst,
• 14 - turbocharger,
• 15 - clamping bracket, 40 Nm,
• 16 - central muffler

Bracket elements for supporting the exhaust inlet pipe

• 1 - buffer,
• 2 - bushing,
• 3 - washer,
• 4 - left overlay,
• 5 - washer,
• 6 - bolt,
• 7 - bushing,
• 8 - right overlay,
• 9 - spring,
• 10 - bolt,
• 11 - self-locking nut, 25 Nm

Distance (a) by which the exhaust system must be offset during installation

• a = 7 - 9 mm.

The arrow indicates the direction of the vehicle's movement.



The exhaust system consists of an exhaust manifold, a turbocharger, an exhaust pipe, a central muffler and an additional muffler.

Vehicles with V6 engines are equipped with two separate exhaust systems.

On all-wheel drive vehicles, a dual rear muffler is installed.

The connection of the exhaust system elements is carried out using threaded connections or clamps.

The purpose of the exhaust system is to remove exhaust gases into the atmosphere so that even a minimal amount of them does not enter the car's interior, as well as to reduce engine noise to a low level. In order for the exhaust system to perform its functions, it must be in good condition.

The condition of the exhaust system also affects engine power and fuel consumption.

Removal

The fuel system can be removed either as a whole or in separate sections.

1. Raise the vehicle and secure it on stands.

2. Remove the lower engine splash shield.

3. Apply a rust destroying agent to the nuts and bolts that fasten the exhaust system components. Wait for some time until the rust is completely destroyed.

Petrol engines

1. Disconnect the oxygen sensor electrical connector. On six-cylinder engines, disconnect the connectors from both oxygen sensors. The oxygen sensor connectors are located on the engine compartment bulkhead.

2. Unscrew the front exhaust pipe bracket from the exhaust manifold. Support the exhaust system with a jack or tie it with wire to the underbody of the car.

1.8-I ADR and six-cylinder engines

1. Unscrew the exhaust pipe mount to the bracket located on the gearbox.


2. Release the exhaust system from the rubber mounts and remove it from under the vehicle.

Installation

1. To make it easier to unscrew the nuts and bolts securing the exhaust system, lubricate them with Liqui Moly LM-508-ASC high-temperature paste.

2. Before reconnecting the exhaust system components, clean the connection with sandpaper to remove any remaining sealant or rust.

1.8-I ADR engine and six-cylinder engine

1. Unscrew the exhaust pipe support bracket from the gearbox, see Fig. Exhaust pipe support bracket components.

2. Install the exhaust system components into the rubber mounts, but do not tighten the bolts at this stage.

3. Bolt the catalytic converter with a new gasket to the exhaust pipe, but do not tighten the bolts completely at this stage.

4. If necessary, rotate the exhaust system sections so that the entire exhaust system is located at least 25 mm from the body.

5. Move the exhaust system so that the exhaust system mount in the rubber cushions is moved forward by 7-9 mm (see Fig. Distance (a) by which the exhaust system must be moved during installation). This is necessary so that when the exhaust system heats up and expands thermally, it is installed in the correct position.

6. Finally tighten all nuts and bolts securing the exhaust system (see table Tightening torques).

7. Install the lower engine cover.

8. Connect the oxygen sensor electrical connectors.

9. Lower the car to the ground.

10. Start the engine and check the exhaust system for leaks.