Exhaust System (Front Wheel Drive)

Exhaust System For Vehicles With Front Wheel Drive (FWD) - Component Overview

Component Locations, Overview:

1 23 Nm
2 Suspended mount
- Replace if damaged
3 Front exhaust pipe with catalytic converter
- for cylinder bank 1 (right)
- with decoupling element
- Decoupling element must not be kinked more than 10 degree, otherwise it may be damaged
- Protect from hit- and impact stress
- Install exhaust system free of stress
- Individual mounting components for vehicles with manual transmission, See Fig. 4
- Individual mounting components for vehicles with automatic transmission 01J, See Fig. 6
4 27 Nm
- replace
5 Exhaust manifold
- for cylinder bank 1 (right)
6 Seal
- replace
7 Heated Oxygen Sensor (HO2S) -G39- (before catalytic converter)
- Bank 1, sensor 1
- The threads of new oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body
- When re-using the old oxygen sensor, grease the threads with hot bolt paste; the paste must not get into slots of oxygen sensor body.
- Tighten to 55 Nm
8 Heated Oxygen Sensor (HO2S) 2 -G108- (before catalytic converter)
- Bank 2, sensor 1
- The threads of new oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body
- When re-using the old oxygen sensor, grease the threads with hot bolt paste; the paste must not get into slots of oxygen sensor body.
- Tighten to 55 Nm
9 Exhaust manifold
- for cylinder bank 2 (left)
10 Seal
- replace
11 27 Nm
- replace
12 Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) -G131-
- Bank 2, sensor 2
- Check Oxygen Sensor (O2S) and oxygen sensor control behind Three Way Catalytic Converter (TWC)
- The threads of new oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body
- When re-using the old oxygen sensor, grease the threads with hot bolt paste; the paste must not get into slots of oxygen sensor body.
- Tighten to 55 Nm
13 Front exhaust pipe with catalytic converter
- for cylinder bank 2 (left)
- with decoupling element
- Decoupling element must not be kinked more than 10 degree, otherwise it may be damaged
- Protect from hit- and impact stress
- Install exhaust system free of stress
- Individual mounting components for vehicles with manual transmission, See Fig.3
- Individual mounting components for vehicles with automatic transmission 01J, See Fig. 5
14 Front clamping sleeve
- Before tightening ensure exhaust system is tension-free
- Installed position, See Fig. 1
- Tighten bolts evenly
15 40 Nm
16 Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- with Oxygen Sensor (O2S) Heater 1 -Z29-
- Bank 1, sensor 2
- The threads of new oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body
- When re-using the old oxygen sensor, grease the threads with hot bolt paste; the paste must not get into slots of oxygen sensor body.
- Tighten to 55 Nm
17 Suspended mount
- Replace if damaged
18 23 Nm
19 Rear muffler
- with exhaust flap
- Factory-installed with center muffler as one unit. If repair is necessary, replace separately
- Install exhaust system free of stress
20 Rear clamping sleeve
- Used when center or rear muffler is replaced separately.
- Before tightening ensure exhaust system is tension-free
- Installed position, See Fig. 2
- Tighten bolts evenly
21 40 Nm
22 Center muffler
- Factory-installed with rear muffler as one unit. If repair is necessary, replace separately
- Install exhaust system free of stress
23 Suspended mount
- Replace if damaged
24 23 Nm

Fig. 1 Installed position of front clamping sleeves







- Install double clamps so that the bolt ends do not project beyond lower edge of double clamp.
- Threaded connections face each other

Fig. 2 Installed position of rear clamping sleeve







- Alpha = 30 degree
- Bolt heads (arrow) face toward fuel tank -1-

Fig. 3 Individual left mounting components for vehicles with manual transmission







1 Bolt (25 Nm)
2 Spacer sleeve
3 Strap
4 Buffer
5 Washer
6 Bolt (25 Nm)
7 Washer
8 Compression spring
9 Spacer sleeve
10 Self-locking nut (25 Nm)

Fig. 4 Individual right mounting components for vehicles with manual transmission







1 Self-locking nut (25 Nm)
2 Washer
3 Washer
4 Buffer
5 Spacer sleeve
6 Washer
7 Washer
8 Bolt (25 Nm)
9 Spacer sleeve
10 Strap
11 Strap
12 Compression spring
13 Washer
14 Bolt (25 Nm)

Fig. 5 Individual left mounting components for vehicles with automatic transmission 01J







1 Self-locking nut (25 Nm)
2 Washer
3 Bracket
4 Strap
5 Buffer
6 Spacer sleeve
7 Bolt (25 Nm)
8 Bolt (25 Nm)
9 Washer
10 Compression spring
11 Bolt (25 Nm)
12 Spacer sleeve
13 Self-locking nut (25 Nm)

Fig. 6 Individual right mounting components for vehicles with automatic transmission 01J







1 Spacer sleeve
2 Strap
3 Buffer
4 Spacer sleeve
5 Bolt (25 Nm)
6 Bolt (25 Nm)
7 Washer
8 Compression spring
9 Spacer sleeve
10 Washer
11 Self-locking nut (25 Nm)