Front And Rear Mufflers, Separating And Connecting

WARNING: This page is about a different car, the 2006 Volkswagen Jetta and 2005 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

A separating point has been provided in the connecting pipe for individual replacement of the front or rear muffler.
The separating point is marked by depressions around the circumference of the exhaust pipe.

Special tools and workshop equipment required

body repair saw V.A.G 1523 A
or chain pipe cutter VAS 6254
Protective glasses

Separating

WARNING:

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

-- Cut exhaust pipe at separation point -arrow 2- e.g. using body repair saw V.A.G 1523 A at a right angle.

Fig 1: Identifying Exhaust Pipe Separation Point

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Joining

NOTE:

A second mechanic is required for installing the repair clamp.

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

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

-- Position repair clamp at side markings -arrow 1- and -arrow 3-.

Fig 2: Identifying Installation Position Of Repair Clamp

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Rotate the repair clamp -A-, as illustrated.

-- Adjust the exhaust system when it is cold so that it is free from tension EXHAUST SYSTEM, INSTALLING .

-- Tighten the repair double clamp.

Tightening specification M8: 25 Nm