Removing and installing front exhaust pipe with catalytic converter — VW

🔧 Engine codes this applies to

📋 Procedure

1. ⚠ When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:Route all the various lines (e.g. for fuel, hydraulics, activated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original positions.Ensure that there is sufficient clearance to all moving or hot components. — All cable ties which are opened or cut open when engine is removed must be replaced in the same position when engine is installed.
2. First check whether a coded radio is fitted. If so, obtain anti-theft coding.
3. Switch off ignition and all electrical consumers.
4. Disconnect battery earth strap Electrical system27Battery; Removing and installing battery.
5. Remove intake manifold cover.

6. Unbolt coolant expansion tank and move forwards with hoses still connected.
7. Disconnect connecting hose between air intake elbow and air mass meter.
8. Pull connector off variable intake manifold changeover valve and secondary air inlet valve.
9. Pull off vacuum hoses (1) and (2).
10. Remove bolts/nuts (arrows).
11. Move securing plate for variable intake manifold changeover valve and secondary air inlet valve away forwards.
12. Remove intake elbow with connecting hose.
13. Vehicles with Lambda probes after catalytic converter: disconnect connectors (green and brown) on bulkhead for Lambda probes after catalytic converter and free wiring to gearbox.
14. Disconnect connector for Lambda probes before catalytic converter for cylinder bank 1 (right) or cylinder bank 2 (left), depending on which exhaust pipe is to be disconnected, and free wiring. [Note: Observe allocation of cable ties.]
15. Remove left or right Lambda probe before catalytic converter.
16. Remove left or right drive shaft heat shield (arrows). The third bolt is not visible on illustration.
17. Vehicles with Lambda probes after catalytic converter: free wiring on gearbox for Lambda probes after catalytic converter and separate both cables. [Note: Observe allocation of cable ties.]
18. Unbolt right or left exhaust pipe from exhaust manifold and gearbox support.
19. Loosen left or right double clamp between exhaust pipe and centre silencer and slide clamp to rear.
20. Guide left or right front exhaust pipe with catalytic converter out to rear.
21. On vehicles with four-wheel drive, secure propshaft with assembly tool3213 and remove centre bearing from vehicle floor Automatic gearbox39Removing and installing propshaft. [Note: The propshaft must not be disconnected from the gearbox using this procedure.]
22. Remove upper nut on left or right exhaust manifold (depending on which exhaust pipe is to be removed).
23. Support gearbox Automatic gearbox39Removing and installing gearbox; Removing and installing gearbox on vehicles with a V6 spark ignition engine.
24. Remove bolts (1) and (2) on rear of both sides of subframe.
25. Lower gearbox slightly.
26. Vehicles with Lambda probes after catalytic converter: free wiring on gearbox for Lambda probes after catalytic converter and separate both cables. [Note: Observe allocation of cable ties.]
27. Unbolt right or left exhaust pipe from exhaust manifold and gearbox support.
28. Loosen left or right double clamp between exhaust pipe and centre silencer and slide clamp to rear.
29. Remove left and right gearbox support (1) with gearbox mounting (2). [Note: A second mechanic is required for this.To remove lower gearbox support bolt, raise gearbox slightly and use hexagon key extension, 8 mm3247.To remove upper gearbox support bolt, lower gearbox slightly and swing exhaust pipe upwards as far as possible.]
30. Guide left or right front exhaust pipe with catalytic converter out to rear.
31. ⚠ When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:Route all the various lines (e.g. for fuel, hydraulics, activated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original positions.Ensure that there is sufficient clearance to all moving or hot components. — Install gearbox support and gearbox mounting Automatic gearbox37Removing and installing gearbox; Removing and installing left and right gearbox support.
32. Secure subframe to body Running gear, axles, steering - front and four-wheel drive40Removing and installing subframe.
33. Bolt propshaft intermediate mounting to vehicle flooring, then remove assembly tool3213 and tighten securing bolts to specified torque settings.
34. Secure Lambda probe wiring as per original routing.
35. Removing and installing front exhaust pipe with catalytic converter and Lambda probes .
36. Install heat shield for drive shafts Running gear, axles, steering - front and four-wheel drive40Repairing drive shafts; Removing and installing drive shafts.
37. Install variable intake manifold changeover valve securing plate .
38. Install air intake elbow .
39. Read fault memories of all control units, rectify faults as necessary and then erase fault memories Vehicle diagnosis, test and information systemVAS 5051; Guided fault finding; Vehicle system test, or Vehicle diagnosis and service information systemVAS 5052; Vehicle self-diagnosis.
40. Carry out road test and again read fault memories of all control units. [Note: Observe applicable safety precautions during road test .]

Other VW procedures

• Testing fuel pump control unit -J538
• Checking combination valve for secondary air system for proper operation and leakage
• Removing sump (bottom section)
• Removing and installing oil seal on camshaft toothed belt pulley
• Testing lambda probe signal wiring and activation
• Removing engine · 41 torque figures
• Removing and installing camshaft · 47 torque figures
• Adjusting valve timing · 83 torque figures
• Removing and installing camshafts · 39 torque figures
• Removing and installing coolant pump · 53 torque figures