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Home >> Volkswagen >> 2009 >> GLI 2.0 J, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 192 (1.9L - Exhaust System, Emission Controls - Engine Code(S): BKC, BLS, BRM & BXE (A5 Platform)) >> 26 Exhaust System, Emission Controls >> Description And Operation >> Exhaust System Assembly Overview

Exhaust System Assembly Overview

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.
CAUTION:

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

  • Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
  • Ensure sufficient clearance to all moving or hot components.
NOTE:

Flex joint in front exhaust pipe must not be bent more than 10 degrees, otherwise it may be damaged.

Replace gaskets and self-locking nuts.

After exhaust system repairs, make sure exhaust system is not under stress and is far enough from the body. If necessary, loosen clamp and align muffler and exhaust pipe such that there is adequate distance to body and weight is evenly distributed among the suspended mounts.

Exhaust manifold and turbocharger are one component, removing and installing TURBOCHARGER .

Fig 1: Identifying Exhaust System Components, Assembly Overview
GWWM26-0183Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
  1. Front exhaust pipe with catalytic converter 
  2. Oxygen sensor -G39- 
    • Threads of new oxygen sensors are coated with assembly paste
    • When using an oxygen sensor once again, only use hot bolt paste G 052 112 A3 to grease the thread; do not let paste get onto slits of oxygen sensor body
    • Use ring spanner set for oxygen sensor 3337 for removal and installation
  3. Clamp 
    • Replace
  4. Gasket 
    • Replace
    • Note installation position
  5. 7 Nm 
  6. Suspended mount 
    • Replace if damaged
  7. 25 Nm 
  8. Clamp 
  9. 25 Nm 
  10. Retaining ring, front muffler 
    • Replace if damaged
  11. Front and rear muffler 
    • For repairs, replace each separately
  12. Suspended mount 
  13. Separating point 
    • For repairs
    • Marked by three depressions around the circumference of the exhaust pipe
    • At factory, front and rear mufflers are installed as a single component. Replacement front and rear mufflers are supplied separately.
    • Use a clamp for connecting.
    • Separating and joining front and rear mufflers FRONT AND REAR MUFFLERS, SEPARATING AND CONNECTING .
    • Installation location, rear clamp (repair double clamp) Figure
    • Evenly tighten the clamp threaded connections (repair double clamp).
    • Clamp tightening specification (repair double clamp): M8 = 25 Nm
    • Install exhaust system free of stress EXHAUST SYSTEM, INSTALLING .
  14. Suspended mount 
  15. 40 Nm 
  16. Support 
  17. 40 Nm 
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