Front And Rear Mufflers, Separating And Connecting

WARNING: This page is about a different car, the 2008 Volkswagen Jetta, 2008 Volkswagen GLI, 2007 Volkswagen Jetta, and 2006 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 VAG 1523A or
Chain pipe cutter VAS 6254
Protective eyewear

Separating

WARNING:

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

-- Cut the exhaust pipe at the separation point -arrow 2- using the VAG 1523A or the VAS 6254 at a right angle.

Fig 1: Identifying Exhaust Pipe Separation Point

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Connecting

NOTE:

A second mechanic is required for installing the repair clamp.

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

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

-- Position the repair clamp at the side markings -arrows 1 and 3-.

-- Rotate the repair clamp -A-, as shown and tighten.

Fig 2: Identifying Installation Position Of Repair Clamp

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Tightening specification: 25 Nm.

-- Align the exhaust system free of tension. Refer to EXHAUST SYSTEM, INSTALLING .