Front And Rear Mufflers, Separating And Connecting

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.

NOTE:

A separating point has been provided in the connecting pipe for removing, installing and replacing the front and rear muffler.

The separating point is marked by depressions around the circumference of the exhaust pipe.

Special tools and workshop equipment required

Body Saw V.A.G 1523 A
Chain Pipe Cutter VAS 6254
Torque Wrench (5-50 Nm) V.A.G 1331
Protective Eyewear
Protective Clothing

Separating

WARNING:

To prevent injuries from metal shavings, wear protective goggles and protective clothing.

-- Cut the exhaust pipe at the separation point -arrow 2- using, for example, the body saw V.A.G 1523 A or the chain pipe cutter VAS 6254 at a right angle.

Fig 1: Identifying Exhaust Pipe Separation Point

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Joining

NOTE:

A second technician is needed when tightening the rear clamping sleeve (clamping sleeve repair).

-- Secure the front muffler in the retainers. The front clamp remains loosely connected to the pipes.

-- Align the rear muffler horizontally and hold it in this position.

-- When installing, position the rear clamping sleeve at the side marks -arrows 1 and 3-.

Fig 2: Identifying Exhaust Pipe Separation Point

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Position the rear repair clamp -A- as shown and tighten it to 23 Nm.

Fig 3: Identifying Installation Position Of Repair Clamp

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Then, align the exhaust system free of tension. Refer to EXHAUST SYSTEM, ALIGNING .