Contents: Removal ↓ Installation ↓
Removal
Before removing, spray all threaded connections with a corrosion dissolving agent.
Unscrew 2 bolts on each side of the muffler-pipe connection flange from below and remove the muffler downwards.
If it is necessary to remove the pipe, first remove the muffler.
Engines with catalytic converters: Disconnect the lambda probe connector.
Carburetor engines: Remove the two intake air heating hoses from the right pipe.
Unscrew the pipe from the cylinder head.
Installation
Clean all contact surfaces, be sure to replace all gaskets.
Attention engines with a working volume of 1.9 l: Since 7.84, reinforced pipes are installed between the cylinder heads and the muffler. The old pipes are no longer supplied as spare parts. To install them on cars manufactured before 7.84, some additional work must be carried out so that the pipe does not touch any elements of the car.
Before installing the left pipe, cut off the lug on the thermostat housing cover "arrow" in accordance with the shaded part in the figure.
Bend the hose shield "arrow B" so that the distance to the pipe is at least 2 mm.
Place the pipe on the cylinder head with a new gasket and tighten the nut by hand.
Caution: Install the gasket with the metal side facing the cylinder head.
Install the muffler with new gaskets, tighten the bolts by hand.
Note: Where applicable, tighten the left and right muffler mounting brackets.
Tighten the bolts on the cylinder head and the muffler-pipe connections to a torque of 20 Nm.
Carburetor engines: Connect to the right pipe of the intake air heating hose.
Engines with catalytic converters: If removed, install a new lambda probe. Coat only the threaded part of the lambda probe with special VAG G5 grease. G5 should not get into the openings or holes of the sensor body. If possible, do not touch or contaminate the body of the new lambda probe. Screw the lambda probe into the catalytic converter with a tightening torque of 50 Nm. Connect the lambda probe connector.
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