Exhaust manifold, front exhaust pipe with Three Way Catalytic Converter (TWC) and attachments (vehicles with engine code BDF)

WARNING: This page does not describe the selected car, but rather 14 other vehicles, including the 2005 Volkswagen GTI, 2004 Volkswagen R32, 2004 Volkswagen Jetta, 2004 Volkswagen GTI, and 2003 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Exhaust Manifold, Front Exhaust Pipe And Catalytic Converter With Attachments (Vehicles With Engine Code BDF)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Gasket

replace
2-piece
Note installation position

2 - Exhaust manifold

2-piece

3 - 25 Nm

replace

4 - 23 Nm

5 - 13 Nm

6 - 25 Nm

7 - Heat shield

8 - 10 Nm

Fig 2: Exhaust Manifold, Front Exhaust Pipe And Catalytic Converter With Attachments (Vehicles With Engine Code BDF)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

9 - Coolant pipe

Secured together with heat shield to exhaust manifold

10 - Connector

Black, 6-pin
Terminals are gold-plated
Component location: At right vehicle underside

11 - Heated Oxygen Sensor (HO2S) -G39-* bank 1, 50 Nm

Component location: in front catalytic converter
Only grease threads with G 052 112 A3 hot bolt paste, do NOT allow hot bolt paste to get into slots on sensor body
Voltage supply of oxygen sensor heater via Fuel Pump (FP) Relay -J17-
Check oxygen sensor heater for Oxygen Sensor (O2S) before Three Way Catalytic Converter (TWC). Refer to Oxygen sensor heater for oxygen sensors before catalytic converter, checking

Check Oxygen Sensor (O2S) and oxygen sensor control before Three Way Catalytic Converter (TWC). Refer to Oxygen sensors and oxygen sensor regulation before catalytic converter, checking

Fig 3: Exhaust Manifold, Front Exhaust Pipe And Catalytic Converter With Attachments (Vehicles With Engine Code BDF)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

12 - Connector

Black, 4-pin
Terminals 3 and 4 gold-plated
Component location: At right vehicle underside

13 - Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-* bank 1, 50 Nm

Component location: In rear catalytic converter
Only grease threads with G 052 112 A3 hot bolt paste, do NOT allow hot bolt paste to get into slots on sensor body
Voltage supply of oxygen sensor heater via Fuel Pump (FP) Relay -J17-
Check oxygen sensor heater for Oxygen Sensor (O2S) behind Three Way Catalytic Converter (TWC). Refer to Oxygen sensor heater for oxygen sensors behind Three Way Catalytic Converter (TWC), checking

Check Oxygen Sensor (O2S) and oxygen sensor control behind Three Way Catalytic Converter (TWC). Refer to Oxygen sensors and oxygen sensor regulation behind catalytic converter, checking

14 - Front exhaust pipe with catalytic converter

Check catalytic converter. Refer to Three Way Catalytic Converter (TWC), checking

Fig 4: Exhaust Manifold, Front Exhaust Pipe And Catalytic Converter With Attachments (Vehicles With Engine Code BDF)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

15 - to front muffler

Refer to Muffler with mounts (vehicles with engine codes AFP and BDF) , item 1

16 - 5 Nm

17 - Heat shield

for catalytic converter

18 - Mounting clip

replace
Slide on to bracket from rear before tightening securing bolt.

19 - 40 Nm

replace

20 - Gasket

replace
2-piece