Exhaust system components, removing and installing

Notes:
^ Always replace seals and gaskets, self - locking nuts and clamps.
^ After on the exhaust system ensure that the system is not under stress, and that it has sufficient clearance from the bodywork. If necessary, loosen clamp and align silencers and exhaust pipe so that sufficient clearance is maintained to the bodywork at all points and the mountings are evenly loaded.
^ Loosen and tighten clamping plates for heat shields with a screwdriver. Tightening torque: 2 Nm
^ De - coupling element on front exhaust pipe may only be bent slightly (not more than 10°)
^ If droning noises can be heard after aligning the exhaust system, adjust the engine mountings.





Exhaust System, Front - Wheel - Drive Vehicles
1 - Tunnel cross - piece
^ With drilling for aligning exhaust system, Refer to Stress-free alignment of exhaust system.
2 - Mounting
^ Position, Refer to Fig 2
3 - 25 Nm
4 - Front exhaust pipe
^ With catalytic converter
^ With de - coupling element
^ Protect from damage by knocks and impact
^ De - coupling element may only be bent slightly (not more than 10°)
^ Removing and installing, Refer to Exhaust Pipe, Service and Repair.
5 - 40 Nm
^ Replace
6 - Spacer sleeve
^ For all four nuts
7 - Gasket
^ Replace
8 - Turbocharger
^ Removing and installing, Refer to Powertrain Management.
9 - Lambda probe - 55 Nm
^ Grease only the threads with "G5;" "G5" must not get into the slots on the probe body
^ Lambda probe connector is located under a protective cover
10 - Lambda probe after catalytic converter - 55 Nm
^ Grease only the threads with "G5;" "G5" must not get into the slots on the probe body
^ Lambda probe connector is located under a protective cover
11 - Clamp
^ Align exhaust system so it is free of stress before tightening clamp.
- Installation position: horizontal in vehicle, bolted connection facing to left
^ Tighten bolted connections evenly.
12 - 40 Nm
13 - Mounting
14 - 25 Nm
15 - Front and rear silencers
^ Can be replaced separately
^ Exhaust pipe with cutting point
^ Aligning exhaust system free of stress.
16 - Mounting
17 - 25 Nm
18 - 25 Nm





Exhaust System, All - Wheel - Drive Vehicles
1 - Turbocharger
^ Removing and installing, Refer to Powertrain Management.
2 - Gasket
^ Replace
3 - Front exhaust pipe
^ With de - coupling element
^ Protect from damage by knocks and impact
^ De - coupling element may only be bent slightly (not more than 10°)
^ Removing and installing, Refer to Exhaust Pipe, Service and Repair.
4 - Lambda probe before catalytic converter - 55 Nm
^ Grease only the threads with "G5;" "G5" must not get into the slots on the probe body
^ Lambda probe connector is located under a protective cover - Lambda probe after catalytic converter - 55 Nm
^ Grease only the threads with "G5;" "G5" must not get into the slots on the probe body
^ Lambda probe connector is located under a protective cover.
5 - 40 Nm
^ Replace
6 - Catalytic converter
^ Removing and installing, Refer to Exhaust Pipe, Service and Repair.
7 - Mounting
^ Loosen mounting to center tailpipe in relation to bumper.
8 - 25 Nm
9 - Front and rear silencers
^ Can be replaced separately
^ Exhaust pipe with cutting point
^ Aligning exhaust system free of stress.
10 - 25 Nm
11 - Mounting
12 - Rubber hanger
13 - 25 Nm
14 - Retainer hose
15 - Clamp
^ Align exhaust system so it is free of stress before tightening clamp.
- Installation position: horizontal in vehicle, bolted connection facing to the left -
^ Tighten bolted connections evenly.
16 - Gaskets
^ Replace
- Installation position: horizontal in vehicle, bolted connection facing to the left -
^ Tighten bolted connections evenly.
17 - 25 Nm
18 - 40 Nm
19 - Spacer sleeve
^ For all four nuts





Fig. 1 Marked position for cutting exhaust pipe
^ For individual replacement of front or rear silencer.
^ Position is marked with three indentations on exhaust pipe.

^ Cut through exhaust pipe at right angles with body saw (e.g. V.A.G 1523) at position marked - arrow 2 -.
^ Position clamp - 4 - between side markings - arrows - 1 - and - 3 - when installing.
^ Aligning exhaust system free of stress.
^ Align rear silencer so it is horizontal.
^ Tighten bolted connections on clamp evenly to 40 Nm.
^ Installation position of clamp: horizontal in vehicle, bolted connections facing front.





Fig. 2 Installation position of mounting
Angled end of base of mounting - arrow - faces in direction of travel.





Fig. 3 Gap between exhaust pipe and heat shield for steering box: at least 24 mm
^ To measure the gap, fit a 17 mm 1/2" socket (outside diameter approximately 24 mm) to a long extension and insert between front exhaust pipe and heat shield. The gap should be large enough to allow the socket to be inserted without difficulty.