Left Front Exhaust Pipe With Front and Main Catalytic Converter, M/T, Removing and Installing
Left Front Exhaust Pipe With Front And Main Catalytic Converter, Removing And Installing (Vehicles With Manual Transmission)
Special tools, testers and auxiliary items required
- Hose clamps up to 25 mm diameter 3094
- Engine/transmission jack V.A.G 1383 A
Removing
NOTE: All cable ties opened or cut during repairs must be reinstalled at the same locations.
- Remove rear engine cover - arrows -.
- Remove cover - 1 - in engine compartment (left side).
- Clamp off coolant hose - 2 - using hose clamp 3094 and disconnect from coolant expansion tank.
- Seal connection using a plug that fits.
- Remove bolt from coolant reservoir - arrow -.
- Disconnect electrical wiring to Engine Coolant Level (ECL) Warning Switch -F66- at bottom on expansion tank and set aside coolant expansion tank with coolant hose - 1 - connected.
- Remove harness connectors - 1 to 4 - from bracket at left of bulkhead.
- Disconnect electrical harness connectors - 1 - and - 4 -.
- Remove bracket from bulkhead.
- Remove heat insulation sleeve on wiring harness and lay wiring harness clear.
- Move oxygen sensor wires downward and clear.
- Remove left front wheel.
- Loosen quick-release screws - 1 -, remove screws - 2 - and remove sound insulation.
- Remove bracket for sound insulation - arrows -.
NOTE: Flex joint in front exhaust pipe must not be bent more than 10, otherwise it may be damaged.
- Disconnect exhaust system at left double clamp - left arrow -.
- Place plunger of engine/transmission jack V.A.G 1383 A with a block of wood inserted in between - arrow - beneath rear crossmember.
- Remove bolts - 1 - and - 2 -, then bolts - 3 - and - 4 -.
- Slowly lower rear crossmember using engine/transmission jack V.A.G 1383 A until distance between rear crossmember/chassis acquires dimension - x -.
- Dimension - x - = 60 mm.
NOTE: Transmission must not be lowered further because driveshaft joint and decoupling element in front exhaust pipe may be damaged.
- Remove heat shield for left and right drive axles - arrow -.
- Disconnect connecting rod - 2 - of shift rod.
- Remove socket head bolt of pivot rod - 1 -.
- Move oxygen sensor wiring clear at areas indicated by - arrows - on transmission.
NOTE: Illustration shows engine/transmission assembly removed.
- Unscrew bolt - arrow - at strap for left front exhaust pipe.
- Remove nuts - 1 to 3 - for left front exhaust pipe/exhaust manifold.
NOTE: Illustration shows engine removed.
- Pull front exhaust pipe off of left exhaust manifold.
- Remove front exhaust pipe with front and main catalytic converters.
Installing
Installation is performed in reverse order of removal. Note the following:
NOTE:
- Replace self-locking nuts.
- Secure all hose connections using hose clamps appropriate for the model type Parts Catalog
- During installation, reinstall all cable ties at the same locations.
- Tighten nuts - 1 to 3 - of front exhaust pipe/exhaust manifold bolts uniformly in stages. Align catalytic converter horizontally while tightening.
- Install subframe.
NOTE: Individual mounting components of exhaust system on transmission
- Align exhaust system free of tension
Tightening torques
Component Nm
Front exhaust pipe with front 27
and main catalytic converters
to exhaust manifold.
Front exhaust pipe with front 25
and main catalytic converters
to mounting strap.
Pivot rod to transmission 40
Connecting rod for shift rod 23
to transmission.
Drive axle protection to 23
transmission.