Exhaust System Overview

Fig 1: Identifying Exhaust System Overview

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Heated Oxygen Sensor -G39- 
   • 55 Nm
   • Bank 1 sensor 1
   • Lubricate the threads with hot bolt paste.
   • Make sure the hot bolt paste does not get into the slits in the sensor body.
2. Front Exhaust Pipe with Catalytic Converter 
   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.
   • Protect the catalytic converter from shocks and impact stress.
   • Removing and installing, refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER .
   • Align the exhaust system free of stress. Refer to EXHAUST SYSTEM, ALIGNING .
   • Exhaust system, checking for leaks. Refer to EXHAUST SYSTEM, CHECKING FOR LEAKS .
3. Heated Oxygen Sensor 2 -G108- 
   • 55 Nm
   • Bank 1 sensor 2
   • Lubricate the threads with hot bolt paste.
   • Make sure the hot bolt paste does not get into the slits in the sensor body.
4. Oxygen Sensor after Three Way Catalytic Converter -G130- 
   • 55 Nm
   • Bank 1 sensor 2.
   • Lubricate the threads with hot bolt paste.
   • Make sure the hot bolt paste does not get into the slits in the sensor body.
5. Retaining Loop 
   • Replace if damaged.
   • Follow the part number.
6. Bolt 
   • 23 Nm
7. Suspended Mount 
   • Replace if damaged.
8. Rear Muffler 
   • Is original equipment as one unit with the front muffler. For repairs, replace each separately.
   • Exhaust system, separating and connecting. Refer to FRONT AND REAR MUFFLERS, SEPARATING AND CONNECTING .
   • Align the exhaust system free of stress. Refer to EXHAUST SYSTEM, ALIGNING .
   • Exhaust system, checking for leaks. Refer to EXHAUST SYSTEM, CHECKING FOR LEAKS .
9. Nut 
   • 23 Nm
10. Rear Clamping Sleeve 
    • For individual replacement of the front and rear mufflers.
    • Note the installed position, refer to Fig 2.
    • Tighten the nuts evenly.
11. Retaining Loop 
    • Replace if damaged.
    • Follow the part number.
12. Front Muffler 
    • Original equipment as one unit with the rear muffler. For repairs, replace each separately.
    • Exhaust system, separating and connecting. Refer to FRONT AND REAR MUFFLERS, SEPARATING AND CONNECTING .
    • Align the exhaust system free of stress. Refer to EXHAUST SYSTEM, ALIGNING .
    • Exhaust system, checking for leaks. Refer to EXHAUST SYSTEM, CHECKING FOR LEAKS .
13. Front Clamping Sleeve 
    • Before tightening the exhaust system, adjust it when it is cold so that it is free of tension. Refer to EXHAUST SYSTEM, ALIGNING .
    • Note the installed position, refer to Fig 2.
    • Tighten the bolts evenly.
14. Bolt 
    • 26 Nm
    • Always replace.
    • For attaching the fuel tank.
15. Gasket 
    • Always replace.
16. Nut 
    • 40 Nm
    • Always replace
    • Lubricate the stud bolts on the exhaust manifold with hot bolt paste.

Fig 2: Identifying Clamping Sleeve Location

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- When installing the clamping sleeve, ensure that the bolt end -arrow- does not project beyond the lower edge of clamping sleeve:

• Threaded connection points toward the right.
• Tighten the nuts equally to 23 Nm.