Left Front Exhaust Pipe With Primary and Main Catalytic Converter, Vehicles With Manual Transmission
Left Front Exhaust Pipe with Primary and Main Catalytic Converter, Vehicles with Manual Transmission
Special tools, testers and auxiliary items required
• Hose clamps up to 25 mm diameter (3094)
• Engine/transmission jack (V.A.G 1383 A)
Removing
• All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
- Remove rear engine cover - arrows -.
- Remove cover - 1 - in engine compartment (left side).
- Clamp off coolant hose - 2 - using hose clamp (3094) and disconnect from coolant expansion tank.
- Seal connection using a plug that fits.
- Remove coolant expansion tank - arrow -.
- Disconnect electrical wire to Engine Coolant Level (ECL) Warning Switch (F66) at bottom on expansion tank and set aside coolant expansion tank with coolant hose - 1 - connected.
- Remove electrical harness connectors - 1 to 4 - from bracket at left of bulkhead.
- Disconnect connectors - 1 - and - 4 -.
- Remove bracket from bulkhead.
- Remove heat insulation sleeve on wiring harness and lay open wiring harness.
- Free up oxygen sensor wires downward.
- Remove left front wheel.
- Remove quick-release fasteners - 1 -, remove screws - 2 - and remove noise insulation.
- Remove bracket for noise insulation - arrows -.
• Do not bend the flex joint in front of the exhaust pipe more than 10° or it could be damaged.
- Disconnect exhaust system at left double clamp - left arrow -.
- Place Engine/Transmission Jack (V.A.G 1383 A) plunger with a block of wood inserted in between - arrow - beneath rear crossmember.
- First remove bolts - 1 - and - 2 -, then bolts - 3 - and - 4 -.
- Slowly lower rear crossmember using engine/transmission jack (V.A.G 1383 A) until distance between rear crossmember/chassis acquires dimension - x -.
• Dimension - x - = 60 mm.
• Transmission must not be lowered further because otherwise driveshaft joint and decoupling element in front exhaust pipe may be damaged.
- Remove heat shield for left and right drive axles - arrow -.
- Disconnect connecting rod - 2 - of shift rod.
- Remove socket head bolt of pivot rod - 1 -.
- Free up oxygen sensor wires at areas indicated by - arrows - on transmission.
• Illustration shows engine/transmission assembly removed.
- Remove bolt - arrow - at strap for left front exhaust pipe.
- Remove nuts - 1 to 3 - for left front exhaust pipe/exhaust manifold.
• Illustration shows engine removed.
- Disconnect front exhaust pipe from left exhaust manifold.
- Remove front exhaust pipe with pre and main catalytic converters.
Installing
Installation is in reverse order of removal, note the following:
• Replace self-locking nuts.
• Secure all hose connections using hose clamps appropriate for the model type.
• During installation, all cable ties must be re-installed at the same location.
- Tighten nuts - 1 to 3 - on front exhaust pipe/exhaust manifold bolts uniformly in stages, align catalytic converter horizontally.
- Install subframe.
• Individual mounting components of exhaust system on transmission => [ Individual components of suspension, right side ] Exhaust System Component Overview
- Align exhaust system free of tension. Refer to => [ Exhaust System, Installing ] Exhaust System, Installing.
Tightening Specifications
