Exhaust system, aligning free of stress

Fig 1: Identifying Clearance Between Exhaust Pipe And Heat Shield For Steering Gear

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Clearance between exhaust pipe and heat shield for steering gear should be approx. 30 mm.
• To check this clearance, fit a 22 mm 1/2-inch socket (outside diameter approx. 30 mm) on a long extension and insert between front exhaust pipe and heat shield. The socket attachment must fit easily in the gap.

Fig 2: Aligning Catalytic Converter Horizontally And With Equal Spacing From Heat Shield In Center Tunnel

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Align catalytic converter horizontally -4- and make sure that spacing -3- between catalytic converter and heat shield in tunnel -2- is equal on both sides. Item -1- is the drive shaft.
• Align front and rear silencers centrally and horizontally. If necessary, detach tunnel cross piece.

Fig 3: Aligning Tailpipe In Bumper Cut-Out

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Aligning tailpipe in bumper cut-out

• Align rear silencer to give equal spacing -a- and -b- between tailpipe and bumper cut-out. If necessary, loosen mounts of rear silencer.

On vehicles where the exhaust has been cut through between the front and rear silencers, it may be necessary to loosen the clamp in order to achieve proper alignment.

Fig 4: Installation Position Of Double Clamp

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install clamps so that ends of bolts do not project beyond lower part of clamp circumference.

Fig 5: Positioning Clamp At Distance Of About 5 mm From Notched Markings

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Position clamp at a distance of about 5 mm from the notched markings. Align horizontally, then tighten evenly to 40 Nm.

The bolted connections on the clamp point to the left.