Exhaust System, Installing

Special tools and workshop equipment required 

• Torque Wrench (5-50 Nm) V.A.G 1331

Conditions

• Engine must be cold.

Procedure

-- Loosen the bolts -3 and 4- on the clamping sleeve -1- between the reduction catalytic converter -2- and the front muffler (the -arrow- points in the direction of travel).

Fig 1: Identifying Front Clamping Sleeve Connections

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Align the clamping sleeve -1- to the marking -A- on the reduction catalytic converter -2-.

• Dimension -a- = 5 mm

• The connections must be at the right and must not project beyond the lower edge of the clamping sleeve -arrow-.
  Fig 2: Clamping Sleeve Location

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the front bolt -3- on the clamping sleeve -1- by hand.

Fig 3: Identifying Front Clamping Sleeve Connections

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-- Push the exhaust system as far as possible forward into the double clamp until dimension -a- is reached on the retaining strap (-arrow- points in direction of travel).

Fig 4: Pushing Exhaust System As Far Forward

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• Dimension -a- = 15 to 17 mm.

-- In this position, tighten the bolts -3 and 4- on the clamping sleeve -1- evenly.

Fig 5: Identifying Front Clamping Sleeve Connections

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• Tightening specifications, see -item 8- in EXHAUST DOOR CONTROL UNIT -J883- AND REDUCTION CATALYTIC CONVERTER OVERVIEW .

-- After tightening the clamping sleeve, check dimension -a- and correct if necessary.

Tail Pipe, Aligning

Fig 6: Aligning Exhaust System

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Align rear muffler so that the distance -a- between bumper cut-out and tail pipes is uniform on left and right.