Exhaust System - Removing Spring Clamps Using Wedge Tool
85VW1Applies To RABBIT, AND JETTA DIESELS
FROM 1980
ALL GAS MODELS EXCEPT QUANTUM
AND VANAGON FROM 1983
Group 26
Subject
Exhaust System
Part Identifier N/A
Key Points
Spring clamps, removing/installing with
spring tension wedge set 3140 A161
Number
85-04
October 24, 1985
To separate the exhaust manifold and exhaust pipe you must first remove the two spring clamps, Fig. 1.. This operation is now performed using the 3140 wedge tool set, which supercedes tool 3049A. The set consists of one 3140/1 starting wedge, and two 3140/2 short wedges.
Spring clamps, removing and installing Work sequence
- expand spring clamps by pushing exhaust pipe sideways with large pliers or similar tool, until short wedge 3140/2 can be inserted into spring clamp
Note
When slipping the wedge into the clamp be sure it is completely inserted. The shoulders of the tool should butt against the edge of the clamp.
- push exhaust pipe left to install tool 3140/2 into right clamp, vice versa to install tool in left clamp
- while pushing exhaust pipe to right, and after both short wedges have been installed, remove clamp and wedge as a unit from the left side
- repeat operation for right side to remove remaining clamp and tool
- installation is reverse of removal
- check that installed clamps seat securely in the appropriate notches on manifold and pipe flange
Spring clamps, expanding or releasing
To release tension on a removed spring clamp or to apply tension to a "bare" clamp (new or uninstalled), proceed as follows using a bench vise.
CAUTION
Do NOT attempt to spread a "bare" clamp with the 3140/2 short wedge until first spreading the clamp with the 3140/1 starting wedge. Personal injury as well as tool and clamp damage could result.
Releasing tension Work sequence
- open vise approximately 15 mm (0.060 in)
- place clamp across vise so that blade of installed wedge 3140/2 is between vise jaws
- using plastic mallet, drive starting wedge 3140/1 into the clamp, next to the previously installed 3140/2 short wedge
- turn clamp over and first knock out short wedge 3140/2, then knock out 3140/1 starting wedge
CAUTION
Care must be exercised when you knock wedge tools out of the spring clamps. The combination of the hammer blow and the spring tension will expel the tool with considerable force. Catch the tool with a rag filled box, or other suitable dampening device.
Applying tension Work sequence
- open vise approximately 15 mm (0.060 in)
- place clamp on its side across vise jaws
- using plastic mallet, drive starting wedge 3140/1 into clamp
- using plastic mallet, drive short wedge 3140/2 into clamp until tool shoulder butts clamp edge
- invert clamp and knock starting wedge out of clamp leaving short wedge in place
- spring clamp can now be installed in vehicle (see installing, work sequence)