Exhaust system (vehicles with engine codes AFP and BDF), aligning

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.

Recommended special tools and equipment

Hex bolt M10x80

Fig 1: Identifying Manufactured Alignment Tool

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To align the exhaust system, prepare a special tool from a hex bolt M10x80 to the specified dimensions:

dimension x = 4 mm
dimension y = 25 mm

Work procedure

NOTE:

A second person is required for aligning the exhaust system.
Align exhaust system when cold.
The exhaust system is pretensioned in direction of travel with special tool inserted.

Remove bolts at double clamp. Refer to Muffler with mounts (vehicles with engine codes AFP and BDF) , item 4

Fig 2: Manufactured Tool Inserted Through Rearmost Hole In Tunnel Bridge

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Slide exhaust system as far in the direction of travel until the manufactured special tool can be inserted vertically through rear hole of tunnel bridge (arrow).

Flat side of special tool points to suspension mount bolts of exhaust system.

Fig 3: Installation Position Of The Double Pipe Clamp

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Position new double clamp as shown with approx. 5 mm distance to marking -A- and secure it.

Tightening torque 40 Nm

NOTE: Marking -A- is valid for vehicles with manual and automatic transmission.