Exhaust System Assembly Overview

Fig 1: Identifying Exhaust System, Assembly Overview

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Gasket 
   • Always replace.
2. Heated Oxygen Sensor -G39-, 55 Nm 
   • Threads of the new oxygen sensors are coated with assembly paste
   • When reusing an oxygen sensor again, only use hot bolt paste G 052 112 A3 to grease the threads; do not let the paste get into the slits of the oxygen sensor body.
3. Nut, 40 Nm 
   • Always replace.
   • Coat the stud bolts on the exhaust manifold with hot bolt paste G 052 112 A3.
4. Catalytic Converter 
   • With front exhaust pipe.
   • Protect from shocks and impact stress.
   • With the flex joint.
   • Flex joint must not be bent more than 10 degrees - otherwise it may be damaged.
   • Removing and installing, refer to CATALYTIC CONVERTER WITH FRONT EXHAUST PIPE .
   • Install exhaust system free of stress, refer to EXHAUST SYSTEM, INSTALLING .
5. Oxygen Sensor (O2S) behind Three Way Catalytic Converter (TWC) -G130-, 55 Nm 
   • Threads of new oxygen sensors are coated with assembly paste.
   • When reusing an oxygen sensor again, only use hot bolt paste G 052 112 A3 to grease the threads; do not let the paste get into the slits of the oxygen sensor body.
6. Clamp 
   • Before tightening, ensure the exhaust system is tension-free. Refer to EXHAUST SYSTEM, INSTALLING .
   • Installed location, refer to Fig 2.
   • Tighten the bolts evenly.
7. Nut, 25 Nm 
8. Suspended Mount 
9. Front Muffler 
   • Factory-installed with rear muffler as one unit, to be replaced individually in the event of repairs.
   • Install the exhaust system free of stress. Refer to EXHAUST SYSTEM, INSTALLING .
   • Separating the exhaust system. Refer to FRONT AND REAR MUFFLERS, SEPARATING AND CONNECTING .
10. Retaining Loop 
    • Replace if damaged.
11. Repair Clamp 
    • For individual replacement of the front and rear mufflers.
    • Installed location, refer to FRONT AND REAR MUFFLERS, SEPARATING AND CONNECTING .
    • Tighten the bolts evenly.
12. Rear Muffler 
    • Factory-installed with front muffler as one unit, to be replaced individually in the event of repairs.
    • Install the exhaust system free of stress. Refer to EXHAUST SYSTEM, INSTALLING .
    • Separating the exhaust system, refer to FRONT AND REAR MUFFLERS, SEPARATING AND CONNECTING .
13. Suspended Mount 
    • Replace if damaged.
14. Bolt, 25 Nm 
15. Front Crossmember 
16. Suspended Mount 
    • Replace if damaged.

Fig 2: Identifying Installation Position Of Double Clamp

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-Arrow- points in direction of vehicle travel.

-- Align the clamp -1- with the marking on the pipe -2- :

• -a - = 5 mm
• Bolts must not project beyond the lower edge of the clamp.