Exhaust system components, removing and installing

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.

WARNING: Observe the following for all installations, especially in engine compartment due to lack of room:

Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.

Watch for sufficient clearance to all moving or hot components.

NOTE:

After exhaust system repairs, make sure exhaust system is not under stress and that it has sufficient clearance from the bodywork. If necessary, loosen double clamp(s) and align exhaust pipe so that sufficient clearance is maintained to the bodywork and support rings carry uniform loads.
Do not use any silicone sealant. Traces of silicone components which are sucked into the engine are not burned there, and they damage the oxygen sensors.
Always replace self-locking nuts.
Engine Control Module (ECM) is equipped with On Board Diagnostic (OBD).
Components marked with * are tested via On Board Diagnostic (OBD). Refer to Diagnostic mode 3: Check DTC Memory

Exhaust manifold, front exhaust pipe with Three Way Catalytic Converter (TWC) and attachments:

Vehicles with engine code AFP. Refer to Exhaust manifold, front exhaust pipe with Three Way Catalytic Converter (TWC) and attachments (vehicles with engine code AFP) ,
Vehicles with engine code BDF. Refer to Exhaust manifold, front exhaust pipe with Three Way Catalytic Converter (TWC) and attachments (vehicles with engine code BDF) ,
Vehicles with engine code BJS. Refer to Exhaust manifold, front exhaust pipe with double catalytic converter and attachments (vehicles with engine code BJS) .

Mufflers with mounts:

Vehicles with engine codes AFP and BDF. Refer to Muffler with mounts (vehicles with engine codes AFP and BDF) ,
Vehicles with engine code BJS. Refer to Muffler with mounts (vehicles with engine codes BJS) .

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

Recommended special tools and equipment

Fig 1: 3337 Oxygen Sensor Ring Spanner

Courtesy of VOLKSWAGEN UNITED STATES, INC.

3337 ring spanner 7-piece set

Fig 2: Special Tool - Torque Wrench V.A.G 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

V.A.G 1331 torque wrench (5 to 50 Nm)

without illustration:

V.A.G 1332 torque wrench (40 to 200 Nm)