Front Exhaust Pipe With Catalytic Converter

WARNING: This page is about a different car, the 2010 Volkswagen Jetta, 2009 Volkswagen Jetta, 2009 Volkswagen GLI, 2008 Volkswagen Jetta, and 2008 Volkswagen GLI. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Torque Wrench (5-50 Nm) V.A.G 1331
Hot bolt paste

Removing

Fig 1: Identifying Heated Oxygen Sensor (HO2S) G39 Harness Connector

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-- Disconnect the harness connector for the heated oxygen sensor -G39- -arrow- and free up the wiring harness.

Fig 2: Identifying Front Exhaust Pipe/Turbocharger Nuts

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-- From the top, remove the front exhaust pipe with catalytic converter nuts -arrows- from the turbocharger.

-- Remove the noise insulation. Refer to Description and Operation .

-- Remove nuts accessible from below for the front exhaust pipe with catalytic converter to turbocharger.

-- Remove the nuts -arrows- and slightly pull the underbody cover downward.

Fig 3: Identifying Right Vehicle Floor Cover Nuts

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With Engine Code CBFA:

Fig 4: Identifying 4-Pin Electrical Harness Connector From Oxygen Sensor (O2S) And Three Way Catalytic Converter (TWC) G130

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-- Unclip the wires -arrows-, remove the bracket -2- and disconnect the electrical connectors -1 and 3-.

With Engine Code CCTA:

Fig 5: Identifying Right Side Of The Vehicle Floor Electrical Connector

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-- Disconnect the electrical connector -arrow- on the underbody.

-- Remove the electrical connector out of the bracket and free up the electrical wire to the oxygen sensor.

Continuation for all Engine Codes:

Fig 6: Identifying Exhaust System Bracket

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-- Remove exhaust system suspended mount bolts -arrows-.

-- Remove the front tunnel bridge nuts -arrows- from the underbody.

Fig 7: Identifying Vehicle Floor Front Cross Member

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CAUTION:

Danger of damaging the flex joint:

The flex joint must not be bent more than 10°.
Do not load the flex joint.
Do not damage the wire mesh at the flex joint.

-- Loosen the clamping sleeve -1- and push it rearward.

-- Remove the front exhaust pipe with catalytic converter.

Installing

Tightening specifications, refer to EXHAUST SYSTEM OVERVIEW .
Tunnel bridge to underbody nut: 20 Nm

Install in reverse order of removal. When doing this note the following:

Replace gaskets and self-locking nuts.
Lubricate the stud bolts on the exhaust manifold with hot bolt paste.
Align the exhaust system free of stress. Refer to EXHAUST SYSTEM, ALIGNING .
Check the exhaust system for leaks. Refer to EXHAUST SYSTEM, CHECKING FOR LEAKS .