Removing
Before removal, all threaded connections on the muffler must be treated with a rust dissolving agent.
Raise the rear of the vehicle and place it on stands.
Remove rear engine cover (see section "Removal and installation of a back cover of the engine").
Remove 2 bolts each from both flanges of the exhaust pipe preheating pipes.
Loosen the 2 clamps connecting the heat exchanger and the muffler.
Remove both left and right clamps securing the muffler to the exhaust pipes of the heat exchanger.
Remove the 2 hexagon nuts each on the left and right on the exhaust manifold of the cylinder head.
Remove the carburetor preheater air intake.
The released muffler is first pulled back and then removed downwards.
Installation
To install, use a new exhaust system repair kit with new seals, clips, and bolts. Repair kits (N 111 298 009 A) available at all VW/Audi workshops.
Remove rust and seal residues from the heat exchanger exhaust pipes. Both muffler pipes with flanges used for applying clamps must not have dents.
The old muffler can only be installed again if its body has not rusted.
Lay new gaskets on the cylinder head flanges, slide the muffler from behind over the pipe connection.
Install the carburetor preheater air intake.
Using for fastening connections "exhaust manifold-cylinder head" new self-locking nuts, tighten them uniformly to 20 Nm (2.0 kgcm).
Lay new O-rings on the left and right between the heat exchanger and the muffler, install the clamping clamps and tighten the bolts of their fastening.
Install the clamping clips on the left and right between the muffler and the heat exchanger.
Install new seals on the left and right between the intake manifold flanges and the preheating pipes, carefully tighten the bolts.
Install the rear engine cover.
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