Removing and installing parts of exhaust system — VW

Exhaust manifold, front exhaust pipe and catalyst with attachments for vehicles ▸ 07.95 => Page
26-2

Exhaust manifold, front exhaust pipe and catalyst with attachments for vehicles 08.95 ▸ => Page
26-5

Silencer with mountings => Page
26-9

Exhaust gas recirculation system (Vehicles ▸07.95 only) => Page
26-13

Checking secondary air system for vehicles ▸ 07.95 => Page
26-19

Checking secondary air system for vehicles 08.95 ▸ => Page
26-28

Notes:

After working on the exhaust system ensure that the system is not under stress, and that it has sufficient clearance from the bodywork. If necessary, loosen double and single clamps and align silencer and exhaust pipe so that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded.
Renew self-locking nuts.

Exhaust manifold, front exhaust pipe and catalyst with attachments

Vehicles ▸07.95

Bracket
For warm air collector plate

25 Nm
Warm air collector plate
35 Nm
Exhaust gas recirculation valve
=> Page
26-14
, Item
7

Exhaust gas recirculation temperature sensor
=> Page
26-13
, Item
1

Olive
30 Nm
Exhaust gas recirculation pipe

Lambda probe, 50 Nm
Grease only the threads with "G5"; "G5" must not get into the slots on the probe body
Remove and install with 3337
Checking:

=> Repair group 24; servicing injection and ignition system
4-Cyl. Injection Engine, Mechanic
servicing injection and ignition system

Catalyst
Sealing ring
Renew

40 Nm
Tightening sequence => Fig.
1

Heat shield
10 Nm

Front exhaust pipe
Gasket
Renew

Exhaust manifold
35 Nm
Connecting union for pipe =>Page
26-21
, item
15

Secondary air inlet

Exhaust manifold, front exhaust pipe and catalyst with attachments

Vehicles08.95 ▸

Bracket
For warm air collector plate

25 Nm
Warm air collector plate
Lambda probe after catalyst (G108)*, 50 Nm
Fitting location: catalyst
Grease only the threads with "G5"; "G5" must not get into the slots on the probe body
Remove and install with 3337
Checking:

=> Repair group 24; servicing injection and ignition system
4-Cyl. Injection Engine, Mechanic
servicing injection and ignition system

Catalyst
Sealing ring
Renew

Lambda probe before catalyst (G39)*, 50 Nm
Fitting location: catalyst
Grease only the threads with "G5"; "G5" must not get into the slots on the probe body
Remove and install with 3337
Checking:

=> Repair group 24; servicing injection and ignition system
4-Cyl. Injection Engine, Mechanic
servicing injection and ignition system

40 Nm
Tightening sequence => Fig.
1

Heat shield
10 Nm
Front exhaust pipe

Gasket
Renew

Exhaust manifold
35 Nm
Connecting union for pipe =>Page
26-31
, item
15

Secondary air inlet

Fig. 1
Tightening sequence exhaust pipe to exhaust manifold

Silencer with mountings

Note:

Align the exhaust system longitudinally so that the dimensions -a-, -b- and -c- are maintained.

From catalyst
40 Nm
Double clamp
Intermediate pipe
Clamp
Console
Mounting
25 Nm
Rear silencer

Marking
For clamp
Three times on circumference
Distance clamp/marking => Item
14

Separating point
For repair cases
When replacing central silencer
Marked by three impressions on circumference of connecting pipe
Central and rear silencer are installed as one part as standard. In repair cases the central and rear silencer are supplied individually and a repair connecting pipe with two clamps supplied as joint.
Cut through connecting pipe with body saw e.g. V.A.G 1523 at right angles at the separating point.

Separating point
For repair cases
When replacing rear silencer
Marked by three impressions on circumference of connecting pipe
Central and rear silencer are installed as one part as standard. In repair cases the central and rear silencer are supplied individually and a repair connecting pipe with two clamps supplied as joint.
Cut through connecting pipe with body saw e.g. V.A.G 1523 at right angles at the separating point.

Dimension -b- = approx. 10 mm
Dimension-a- = ca. 5 mm

Marking
Three times on circumference

Marking
Three times on circumference
S = Manual gearbox
A = Auto. gearbox

Repair connecting pipe
Centre silencer