Contents: Removal ↓ Installation ↓
Removal
Before removal, all threaded connections on the muffler must be treated with a rust remover.
Raise the rear of the vehicle and place it on supports.
Remove the rear engine cover (see section "Removal and installation the rear engine cover").
Remove 2 bolts from both flanges of the outlet preheating pipes.
Release the 2 clamps connecting the heat exchanger and muffler.
Remove both clamps on the left and right that secure the muffler to the heat exchanger outlet pipes.
Unscrew 2 hex nuts on the left and right sides of the cylinder head exhaust manifold.
Remove the carburetor preheater air intake.
First pull the released muffler back and then remove it downwards.
Installation
For installation, use a new exhaust system repair kit with new seals, clamps and bolts. Repair kits (N 111 298 009 A) available at all VW/Audi service stations.
Remove rust and sealant residue from the heat exchanger outlet pipes. Both muffler pipes with flanges used for applying clamps must not have any dents.
The old muffler can only be reinstalled if its housing is not rusted.
Place new sealing gaskets on the cylinder head flanges and slide the muffler from behind onto the pipe connection.
Install the carburetor preheater air intake.
Using new self-locking nuts to secure the exhaust manifold-to-cylinder head connections, tighten them evenly to a torque of 20 Nm (2.0 kgfm).
Place new sealing rings between the heat exchanger and the muffler on the left and right, install the clamping clamps and tighten the bolts securing them.
Install clamps on the left and right between the muffler and the heat exchanger.
Install new sealing gaskets on the left and right between the intake manifold flanges and the preheating manifolds, carefully tighten the bolts.
Install the rear engine cover.
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