Removing
Before removing, spray all threaded connections with a corrosion-dissolving agent.
Unscrew the bottom of the muffler-pipe connection flange, 2 bolts on each side and remove the muffler downwards.
If it is necessary to remove the pipe, first remove the muffler.
Engines with catalytic converters: Disconnect 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 displacement of 1.9 liters: From 7.84, reinforced pipes are installed between the cylinder heads and the muffler. the old pipes as spare parts are no longer available. To install them on cars manufactured before 7.84, it is necessary to carry out some additional work so that the pipe does not touch any elements of the car.
Before installing the left pipe, saw off the lug on the cover of the thermostat housing -arrow- in accordance with the shaded part in the figure.
Bend the hose shield -arrow B- so far that the distance to the pipe is at least 2 mm.
Place the pipe on the cylinder head with a new gasket, tighten the nut by hand.
Attention: Install the gasket with the metal side towards the cylinder head.
Install the muffler with new gaskets, tighten the bolts by hand.
Attention: Where present, screw on the left and right muffler mounting brackets.
Tighten the bolts on the cylinder head and muffler-pipe connection to 20 Nm.
Carburetor engines: Connect to the right pipe of the intake air heating hose.
Engines with catalysts: If removed, install a new lambda probe. Coat only the threaded part of the lambda probe with special grease VAG G5. G5 must not fall into openings or holes in 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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