Contents: Removal ↓ Installation ↓
Note: The exhaust system components can be replaced individually. If the pre-silencer or post-silencer of the standard exhaust system has to be replaced, the connecting pipe must be sawn off at the designated point, see also the following chapter. On a vehicle with a 1.4 l diesel engine, the exhaust system consists of two branches, with the catalytic converter located where the pre-silencer is located on other engines.
Removal
Safety instructions: There is a risk of accident when lifting the vehicle! Before carrying out work, read the section "Lifting a car".
Raise the car onto the trestles.
If there is one, remove it lower engine compartment cover.
Spray all bolts and nuts of the exhaust system with a rust converter. Leave the product on the surfaces of the parts for a while to show its effect.
Petrol engine with direct injection: Disconnect the plug connector of the oxygen sensor 1.
Petrol engine: Disconnect the plug connector of oxygen sensor 2.
Depending on the installed engine, unscrew the front exhaust pipe mount from the catalytic converter, exhaust manifold or, respectively, from the turbocharger.
(View the original article on the resource: www.VWManual.ru)
Support or tie the exhaust system to the body with wire so that it does not fall down.
Caution: The flexible connector of the front exhaust pipe must not be bent more than 10°, otherwise it will be damaged.
Unscrew the fastening of the rear holders, lower the rear part of the exhaust system slightly, and remove the subsequent muffler for a dual-flow exhaust system.
Unhook the pre-muffler from the suspension cushion and, together with an assistant, remove the exhaust system.
The exhaust system components can also be replaced individually. If the connecting elements or bolts do not loosen, heat the connection point with a welding torch. Be sure to place an aluminum plate underneath! Caution: Fire hazard!
Installation
Note: Sealing gaskets, nuts and bolts must be replaced. 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. Check the rubber suspension pads for damage and replace if necessary.
If used exhaust system parts are reinstalled, their sealing surfaces must be cleaned with sandpaper to remove carbon deposits and corrosion before connection.
Insert the front exhaust pipe into the suspension mounts, attach it with a new sealing gasket to the catalytic converter, exhaust manifold or turbocharger, respectively, and lightly bolt it on.
Place the preliminary muffler with a double clamp on the front exhaust pipe and screw it together with the suspension to the bottom of the body.
Slide the subsequent muffler with a double repair clamp onto the exhaust pipe of the preliminary muffler and, together with the suspension, screw it to the bottom of the body.
Tighten all bolts, but do not over tighten.
The exhaust system must be aligned so that it is located on the suspensions without stress. The distance of the exhaust system to any parts of the body must be at least 25 mm. If necessary, turn the exhaust system or move it in the longitudinal direction. The suspensions must be loaded evenly. Ensure that the pipes are pushed into the clamps far enough. For control purposes, there are embossings on the pipes at the joints.
Tighten the bolts and nuts. The tightening torque values are given in the explanations to the figures.
Petrol engine: Connect the plug connector of oxygen sensor 2.
Petrol engine with direct injection: Connect the plug connector of the oxygen sensor 1.
If available, install lower engine compartment cover.
Lower the car.
Check the exhaust system for leaks, see the relevant chapter below.
Visitor comments