Exhaust system, component overview: Notes

Fig 1: Exhaust System, Component Overview

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - 23 Nm

2 - Suspended mount

• Replace if damaged

3 - 27 Nm

• Replace
• Tighten uniformly in several stages

4 - Exhaust manifold

• For cylinder bank 1 (right)
• Removing and installing → Right exhaust manifold, removing and installing 

5 - Heated Oxygen Sensor (HO2S) G39 (before catalytic converter)

• For cylinder bank 1 (right)
• 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 previous oxygen sensor, grease threads with hot bolt paste; the paste must not get into slots of oxygen sensor body. Hot bolt paste
• Removing and installing → 24 MULTIPORT FUEL INJECTION (MFI)

6 - 27 Nm

• Replace
• Tighten uniformly in several stages

7 - Exhaust manifold

• Cylinder bank 2 (left)
• Removing and installing → Left exhaust manifold, removing and installing 

8 - Heated Oxygen Sensor (HO2S) 2 G108 (in front of catalytic converter)

• For cylinder bank 2 (left)
• 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 previous oxygen sensor, grease threads with hot bolt paste; the paste must not get into slots of oxygen sensor body. Hot bolt paste
• Removing and installing → 24 MULTIPORT FUEL INJECTION (MFI)

9 - Front exhaust pipe with pre- and main catalytic converters

• For left side of vehicle
• With flex joint
• Decoupling element must not be bent more than 10 ° otherwise it may be damaged
• Protect from hit- and impact stress

• Removing and installing: Vehicles with manual transmission → Left front exhaust pipe with primary and main catalytic converter (vehicles with manual transmission), removing and installing  , vehicles with automatic transmission → Left front exhaust pipe with primary and main catalytic converter (vehicles with automatic transmission), removing and installing 
• Individual mounting components for vehicles with manual transmission Individual left mounting components - vehicles with manual transmission 
• Individual mounting components for vehicles with automatic transmission Individual left mounting components - vehicles with automatic transmission 
• Install exhaust system free of stress → Exhaust system, installing free of tension 

10 - Front clamping sleeve

• Installed location Installed position of front double clamps 
• Before tightening, ensure exhaust system is tension-free → Exhaust system, installing free of tension 
• Tighten bolts evenly

11 - 40 Nm

12 - Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G131

• For cylinder bank 2 (left)
• 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 previous oxygen sensor, grease threads with hot bolt paste; the paste must not get into slots of oxygen sensor body. Hot bolt paste
• Removing and installing → 24 MULTIPORT FUEL INJECTION (MFI)

13 - Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130

• For cylinder bank 1 (right)
• The threads of new oxygen sensors are coated with assembly paste; paste must not get into slots of oxygen sensor body
• When re-using previous oxygen sensor, grease threads with hot bolt paste; the paste must not get into slots of oxygen sensor body. Hot bolt paste
• Removing and installing → 24 MULTIPORT FUEL INJECTION (MFI)

14 - Front exhaust pipe with pre- and main catalytic converters

• For right side of vehicle
• With flex joint
• Decoupling element must not be bent more than 10 ° otherwise it may be damaged
• Protect from hit and impact stress

• Removing and installing: Vehicles with manual transmission → Right front exhaust pipe with primary and main catalytic converter (vehicles with manual transmission), removing and installing  , vehicles with automatic transmission → Right front exhaust pipe with primary and main catalytic converter (vehicles with automatic transmission), removing and installing 
• Individual components of suspension Individual components of suspension, right side 
• Install exhaust system free of stress → Exhaust system, installing free of tension 

15 - Rear muffler

• For left side of vehicle
• Original equipment as one unit with center muffler. For repairs, replace each separately.
• Separating point Separate exhaust pipes at separating point  under Center muffler and rear muffler, separating 
• With exhaust flap - checking exhaust flap → Exhaust flap, checking 

• Install exhaust system free of stress → Exhaust system, installing free of tension 

16 - Suspended mount

• Replace if damaged

17 - 23 Nm

18 - Rear muffler

• For right side of vehicle
• Original equipment as one unit with center muffler. For repairs, replace each separately.
• Separating point Separate exhaust pipes at separating point  under Center muffler and rear muffler, separating 
• With exhaust flap - checking exhaust flap → Exhaust flap, checking 

• Install exhaust system free of stress → Exhaust system, installing free of tension 

19 - 25 Nm

20 - 40 Nm

21 - Rear clamping sleeve

• For individual replacement of center and rear mufflers
• Installed location Installed position of rear double clamps 
• Before tightening, ensure exhaust system is tension-free → Exhaust system, installing free of tension 
• Tighten bolts evenly

22 - Center muffler

• Original equipment as one unit with rear muffler. For repairs, replace each separately.