Front Exhaust Pipe With Catalytic Converter And Attachments Overview

Fig 1: Identifying Front Exhaust Pipe With Catalytic Converter And Attachments (Engine Codes BGP, BTK), Assembly Overview

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Exhaust Manifold 
   • Coat the stud bolts with hot bolt paste G 052 118 A3.
2. Gasket 
   • Always replace.
   • Note the installed position:

     The gasket recess -arrow A- must be located at the exhaust manifold recess -arrow B-.

3. Nut 
   • 23 Nm
   • Always replace.
4. Front Exhaust Pipe with Catalytic Converter 
   • Protect from shocks and impact stress.
   • With a flex joint.
   • The flex joint must not be bent more than 10° - otherwise it may be damaged.
   • Removing and installing, refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER .
   • Install the exhaust system free of stress. Refer to EXHAUST SYSTEM, INSTALLING .
5. Clamp 
   • Before tightening, ensure the exhaust system is free of tension. Refer to EXHAUST SYSTEM, INSTALLING .
   • Installed location, refer to Fig 2.
   • Tighten the nuts evenly.
6. Nut 
   • 23 Nm
7. Nut 
   • 20 Nm
8. Front Crossmember 
9. Oxygen Sensor After Three Way Catalytic Converter -G130- 
   • 55 Nm
   • Use the ring spanner 7-piece set 3337 for removal and installation.
   • The threads of new oxygen sensors are coated with assembly paste.
   • When reusing an old oxygen sensor, only use hot bolt paste G 052 112 A3 to grease the threads; do not let the paste get onto the slits of the oxygen sensor body.
   • If the sealing ring is leaking cut it off and replace it.
10. Connector 
    • Brown, 4-pin
    • Installed location, refer to Fig 3.
11. Bolt 
    • 23 Nm
12. Suspended Mount 
    • Replace if damaged.

Fig 2: Installation Position Of Double Clamp

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The -arrow- points in the direction of travel.

-- Align the clamp -1- to the mark on the catalytic converter -2-.

-a - = 5 mm

The bolts must not project beyond the lower edge of the clamp.

Fig 3: Identifying Harness Connector For Oxygen Sensor - Installation Position

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The harness connector is located on the right side of the vehicle floor under the cover.

1. Bracket 
2. Harness connector for the oxygen sensor after three way catalytic converter, brown 

Fig 1: Identifying Front Exhaust Pipe With Catalytic Converter And Attachments (Engine Code BGQ), Assembly Overview

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Exhaust Manifold 
   • Coat the stud bolts with hot bolt paste G 052 118 A3.
2. Gasket 
   • Always replace.
   • Note the installed position:

     The gasket recess -arrow A- must be located at the exhaust manifold recess -arrow B-.

3. Connector 
   • Black, 4-pin.
4. Oxygen Sensor in Bank 1 Center Three Way Catalytic Converter -G465- 
   • 55 Nm
   • Use the ring spanner 7-piece set 3337 for removal and installation.
   • The threads of new oxygen sensors are coated with assembly paste.
   • When reusing an old oxygen sensor, only use hot bolt paste G 052 112 A3 to grease the threads; do not let the paste get onto the slits of the oxygen sensor body.
   • If the sealing ring is leaking cut it off and replace it.
5. Spring Nut 
   • Insert from the front.
6. Clamp 
   • Before tightening, ensure the exhaust system is free of tension. Refer to EXHAUST SYSTEM, INSTALLING .
   • Installed location, refer to Fig 2.
   • Tighten the nuts evenly.
7. Nut 
   • 23 Nm
8. Nut 
   • 20 Nm
9. Oxygen Sensor After Three Way Catalytic Converter -G130- 
   • 55 Nm
   • Use the ring spanner 7-piece set 3337 for removal and installation.
   • The threads of new oxygen sensors are coated with assembly paste.
   • When reusing an old oxygen sensor, only use hot bolt paste G 052 112 A3 to grease the threads; do not let the paste get onto the slits of the oxygen sensor body.
   • If the sealing ring is leaking cut it off and replace it.
10. Connector 
    • Brown, 4-pin.
    • Installed location, refer to Fig 3.
11. Front Crossmember 
12. Bolt 
    • 5 Nm
13. Heat Shield 
    • For the catalytic converter.
14. Bolt 
    • 23 Nm
15. Suspended Mount 
    • Replace if damaged.
16. Bolt 
    • 10 Nm
17. Front Exhaust Pipe with Catalytic Converter 
    • Protect from shocks and impact stress.
    • With a flex joint.
    • The flex joint must not be bent more than 10°- otherwise it may be damaged.
    • Removing and installing, refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER .
    • Install the exhaust system free of stress. Refer to EXHAUST SYSTEM, INSTALLING .
18. Nut 
    • 23 Nm
    • Always replace.

Fig 2: Installation Position Of Double Clamp

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The -arrow- points in the direction of travel.

-- Align the clamp -1- to the mark on the catalytic converter -2-.

-a - = 5 mm

The bolts must be on the right side. They must not project beyond the lower edge of the clamp.

Fig 3: Identifying Oxygen Sensor (O2S) And Three Way Catalytic Converter (TWC) G130 Electrical Harness Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The harness connectors are located on the right side of the vehicle floor, under the cover.

1. Harness connector for the oxygen sensor after three way catalytic converter, brown 
2. Bracket 
3. Harness connector for oxygen sensor in bank 1 center three way catalytic converter, black