Exhaust manifold, removing and installing

WARNING: This page does not describe the selected car, but rather 20 other vehicles, including the 2009 Volkswagen Golf, 2008 Volkswagen Golf, 2007 Volkswagen Golf, 2006 Volkswagen Golf, and 2005 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and equipment

Fig 1: Torque Wrench V.A.G. 1331 (5 To 50 Nm)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

V.A.G 1331 Torque wrench (5 - 50 Nm)

Removing

Remove engine cover
Remove intake manifold upper part. Refer to Engine code AEG
Remove pressure hose from secondary air pump and combination valve on vehicles with a secondary air system.
Remove middle insulation tray

Refer to NOISE INSULATION (GASOLINE ENGINES), ASSEMBLY OVERVIEW or NOISE INSULATION (DIESEL ENGINES), ASSEMBLY OVERVIEW

Unbolt heat shield for right side drive axle.
Depending on version, remove bolts/nuts for bracket on exhaust manifold and remove it.
For vehicles with secondary air system, remove lower support for combination valve connection pipe to exhaust manifold.
For vehicles with secondary air system, remove upper support for combination valve connection pipe to exhaust manifold.

Depending on version, disconnect Heated Oxygen Sensor (HO2S) -G39-.
Remove warm air collector plate.

Fig 2: Exhaust Pipe Securing Bolts & Nuts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove securing bolts -2- for exhaust pipe on exhaust manifold.
Remove upper four nuts -1- as well as lower four for exhaust manifold to cylinder head.
Take out exhaust manifold upward.

Installing

NOTE:

To prevent exhaust gases from escaping, the contact surfaces between exhaust manifold, exhaust pipe and cylinder head must be bolted together correctly.
Replace all seals and gaskets.

Installation is performed in reverse sequence of removal.