Exhaust Pipe: Service and Repair

Front Exhaust Pipe, Removing And Installing

Removing

NOTE:
- Do not bend the flexible connection (de-coupling element) in the exhaust system more than 10 degrees, otherwise it may be damaged.
- When performing repairs, replace seals, gaskets, self-locking nuts and stretch bolts which have a specified tightening angle.

- Disconnect electrical connector for Oxygen sensor.
- Guide out Oxygen sensor wiring from underneath.







- Remove noise insulation in the center and on left and right sides (arrows).







- Loosen clamp (arrows) on exhaust system and disconnect exhaust pipe.







- Remove catalytic converters from front exhaust pipe (arrows).
- If installed, detach exhaust mounting on subframe.







- Remove drive shaft from flexible coupling on bevel box (arrows).

NOTE: Use a suitable lever to brace the triangular flange when loosening the bolts.







- Remove pendulum support at subframe (arrows -A-).







- Remove steering gear bolts -2-.
- Lever steering gear off subframe (dowel sleeve).
- Place engine/transmission jack V.A.G 1383 A with universal support 1359/2 under subframe.
- Remove subframe bolts -1- and -3-.
- Lower subframe carefully and leave it suspended from the ball joints and connecting links. When doing this, push steering gear upward.
- Remove bracket for power steering pressure pipe from steering gear.
- Remove front exhaust pipe from turbocharger.







NOTE: The upper bolts securing the front exhaust pipe are accessible through the brake line opening in the front wheel housing (remove plug).

Installing

Installation is carried out in the reverse order, when doing this note the following:
- Install subframe as follows:
- Bring subframe into position for installation.
- Insert subframe bolts.
- Bring steering gear into position on subframe and insert steering gear bolts.







- Threaded sleeve -1- should be located in hole in subframe.
- Rubber pad on opposite side should be located on projection on subframe.

- Secure steering gear
- Secure subframe with new bolts;
- Press engine/transmission assembly toward bulkhead, the bevel box pin must be guided carefully into the driveshaft flange when doing this.







NOTE:
- Take care not to damage seals in driveshaft flanges when removing and installing. If a seal is damaged the driveshaft must be replaced.
- Ensure driveshaft is horizontal when pushing onto guide pins.







- Bolt pendulum support to subframe (arrows -A-) (20 Nm plus an additional 1/4 turn (90 degrees).
- Use new bolts for securing.







- Bolt drive shaft to flexible coupling on bevel box (arrows) (60 Nm).
- Aligning exhaust system free of stress.

Tightening torques

Component Nm
Pendulum support to subframe 20 Nm + 90 degrees 1) 2)
Flexible coupling to driveshaft 60 Nm
Front exhaust pipe to turbocharger 40 Nm
Clamp for exhaust pipe 40 Nm

1) 90 degrees = 1/4 turn
2) Replace bolts