Exhaust system components Page 1 / 19
26 - 1
Exhaust system components
Caution!
When doing any repair work, especially in the engine
compartment, pay attention to the following due to
clearance issues:
Route lines of all types (e.g. for fuel, hydraulic,
EVAP canister system, coolant and refrigerant,
brake fluid, vacuum) and electrical wiring so that
the original path is followed.
Ensure sufficient clearance to all moving or hot
components.
Note:
After exhaust system repairs, make sure exhaust
system is not under stress and that it has sufficient
clearance from the bodywork. If necessary, loosen
clamp(s) and align exhaust pipe so that sufficient
clearance is maintained to the bodywork and support
rings carry uniform loads.
Gaskets and self-locking nuts must be replaced.
Exhaust manifold with attachments, assembly overview
26-1, Exhaust manifold with attachments, assembly
overview
Front exhaust pipe with catalytic converter and
attachments (engine code: BGP), assembly overview
26-1, Front exhaust pipe with catalytic converter and
attachment (engine code: BGP), assembly overview,
Front exhaust pipe with catalytic converter and
attachments (engine code BGQ), assembly overview
26-1, Front exhaust pipe with catalytic converter and
attachments (engine code BGQ), assembly overview .
Mufflers with mounts, assembly overview 26-1, Exhaust
system, assembly overview
Front exhaust pipe with catalytic converter, removing and
installing 26-1, Front exhaust pipe with catalytic
converter, removing and installing .
Separating and joining front and rear mufflers 26-1,
Exhaust system components Page 2 / 19
Front and rear mufflers, separating and joining .
Install exhaust system free of stress 26-1, Exhaust
system, installing free of tension
Exhaust manifold with attachments, assembly overview
Gasket
Replace
25 Nm
Replace
Exhaust manifold
Coat stud bolts on cylinder
head with hot bolt paste
Remove upward
Exhaust system components Page 3 / 19
Clip
Heat shield
10 Nm
Oxygen sensor G39
55 Nm
Only use hot bolt paste to
grease thread; do not let
paste get onto slits of
oxygen sensor body
Color of harness connector:
black
Front exhaust pipe with catalytic converter and
attachment (engine code: BGP), assembly overview,
Exhaust system components Page 4 / 19
Exhaust manifold
Coat stud bolts with hot bolt
paste .
Gasket
Replace
Note installation position:
Gasket recess - arrow A - must
be located at exhaust manifold
recess - arrow B - .
25 Nm
Replace
Front exhaust pipe
With catalytic converter
Protect from shocks and
impact stress
With flex joint
Flex joint must not be bent
more than 10 - otherwise it
may be damaged
Removing and installing
26-1, Front exhaust pipe with
catalytic converter, removing
and installing
Install exhaust system free
of stress 26-1, Exhaust
system, installing free of
tension
Clamp
Before tightening, ensure
exhaust system is tension-
free 26-1, Exhaust
system, installing free of
tension
Installed location 26-1,
Installation position of
Exhaust system components Page 5 / 19
clamp
Tighten bolts evenly
25 Nm
23 Nm
Front cross member
Oxygen Sensor (O2S) Behind
Three Way Catalytic Converter
(TWC) G130
55 Nm
Only use hot bolt paste to
grease thread; do not let
paste get onto slits of
oxygen sensor body
Connector
Brown, 4-pin
Installed location 26-1,
Harness connector for
oxygen sensor - installation
position
25 Nm
Suspended mount
Replace if damaged
Installation position of clamp
Exhaust system components Page 6 / 19
- Arrow - points in direction of travel.
- Align clamp - 1 - to marking on catalytic converter - 2 -
.
- a - = 5 mm
Mounting bolts must not project beyond lower edge of
clamp.
Harness connector for oxygen sensor - installation position
Harness connector is located at right on vehicle floor under
cover.
Bracket
Harness connector for Oxygen Sensor (O2S) Behind
Three Way Catalytic Converter (TWC) G130 ,
brown
Front exhaust pipe with catalytic converter and
attachments (engine code BGQ), assembly overview
Exhaust system components Page 7 / 19
Exhaust manifold
Coat stud bolts with hot bolt
paste .
Gasket
Replace
Note installation position:
Gasket recess - arrow A - must
be located at exhaust manifold
recess - arrow B - .
Connector
Black, 4-pin
Oxygen Sensor (O2S (in Center
Exhaust system components Page 8 / 19
Three Way Catalytic Converter
(TWC), Bank 1 G465
55 Nm
Only use hot bolt paste to
grease thread; do not let
paste get onto slits of
oxygen sensor body
Spring nut
Insert from front
Clamp
Before tightening, ensure
exhaust system is tension-
free 26-1, Exhaust
system, installing free of
tension
Installed location 26-1,
Installation position of
clamp
Tighten bolts evenly
25 Nm
23 Nm
Oxygen Sensor (O2S) Behind
Three Way Catalytic Converter
(TWC) G130
55 Nm
Only use hot bolt paste to
grease thread; do not let
paste get onto slits of
oxygen sensor body
Connector
Brown, 4-pin
Installed location 26-1,
Harness connector for
oxygen sensors - installation
position
Exhaust system components Page 9 / 19
Front cross member
5 Nm
Heat shield
For catalytic converter
25 Nm
Suspended mount
Replace if damaged
10 Nm
Front exhaust pipe
With catalytic converter
Protect from shocks and
impact stress
With flex joint
Flex joint must not be bent
more than 10 - otherwise it
may be damaged
Removing and installing
26-1, Front exhaust pipe with
catalytic converter, removing
and installing
Install exhaust system free
of stress 26-1, Exhaust
system, installing free of
tension
25 Nm
Replace
Exhaust system components Page 10 / 19
Installation position of clamp
- Arrow - points in direction of travel.
- Align clamp - 1 - to marking on catalytic converter - 2 -
.
- a - = 5 mm
Mounting bolts must not project beyond lower edge of
clamp.
Harness connector for oxygen sensors - installation position
Harness connectors are located at right on vehicle floor
under cover.
Harness connector for Oxygen Sensor (O2S) Behind
Three Way Catalytic Converter (TWC) G130 ,
brown
Bracket
Harness connector for Oxygen Sensor (O2S (in
Center Three Way Catalytic Converter (TWC), Bank
1 G465 , black
Exhaust system components Page 11 / 19
Exhaust system, assembly overview
Front muffler
Suspended mount
Retaining loop
Replace if damaged
25 Nm
Rear muffler
Factory-installed with front
muffler as one unit. If repair
is necessary, replace
separately.
Install exhaust system free
of stress 26-1, Exhaust
system, installing free of
Exhaust system components Page 12 / 19
tension
Separating exhaust system
26-1, Front and rear
mufflers, separating and
joining
Suspended mount
Replace if damaged
25 Nm
Repair clamp
For individual replacement of
front and rear mufflers
Installed location 26-1,
Front and rear mufflers,
separating and joining
Tighten bolts evenly
Center muffler
Factory-installed with rear
muffler as one unit. If repair
is necessary, replace
separately.
Install exhaust system free
of stress 26-1, Exhaust
system, installing free of
tension
Separating exhaust system
26-1, Front and rear
mufflers, separating and
joining
25 Nm
Front exhaust pipe with catalytic converter, removing
and installing
Special tools, testers and auxiliary items required
Exhaust system components Page 13 / 19
Torque wrench V.A.G 1331
Hot bolt paste Electronic Replacement Parts
Catalog "ETKA"
Removing
- Remove right underbody trim - arrows - .
Engine code BGP
- Unclip wire - arrow - , pull off bracket - 1 - and
disconnect harness connector - 2 - for Oxygen Sensor
(O2S) Behind Three Way Catalytic Converter (TWC)
G130 .
Exhaust system components Page 14 / 19
Engine code BGQ
- Unclip lines - arrows - , pull off bracket - 2 - and
separate connectors - 1 - for Oxygen Sensor (O2S)
Behind Three Way Catalytic Converter (TWC) G130 and -
3 - for Oxygen Sensor (O2S (in Center Three Way
Catalytic Converter (TWC), Bank 1 G465 .
Continued for all
- Loosen bolts of clamp - 1 - . Front cross member for
vehicle floor must not be removed.
Note:
Flex joint in front exhaust pipe must not be bent
more than 10 , otherwise it may be damaged.
Exhaust system components Page 15 / 19
- Remove mounting nuts - 2 - of front exhaust
pipe/exhaust manifold and bolts - 3 - .
- Remove front exhaust pipe - 1 - with catalytic converter
from exhaust manifold, slide toward front at sides and
guide under front cross member.
Installing
Installation is in reverse order of removal. Note the
following:
Replace gaskets and self-locking nuts.
Install exhaust system free of stress 26-1,
Exhaust system, installing free of tension .
Tightening torques:
Component Nm
Front exhaust pipe to exhaust manifold 25 1)
Replace nuts
Mount to subframe 25
Clamp 25
1) Coat stud bolts on exhaust manifold with hot bolt paste .
Front and rear mufflers, separating and joining
Note:
A separating point has been provided in the
connecting pipe for individual replacement of the
front or rear muffler.
Exhaust system components Page 16 / 19
The separating point is marked by depressions
around the circumference of the exhaust pipe.
Special tools, testers and auxiliary items required
Body repair saw V.A.G 1523 A or
Chain pipe cutter VAS 6254
Protective glasses
Separating
Warning!
To prevent injuries from metal shavings, wear
protective goggles and protective clothing.
Exhaust system components Page 17 / 19
- Cut exhaust pipe at separation point - arrow 2 - e.g.
using body repair saw V.A.G 1523 A at a right angle.
Joining
Note:
A second technician is required for installing the
repair clamp.
- Secure front muffler in retainers. The front clamp remains
loosely connected to pipes.
- Align rear muffler horizontally and hold it in this position.
- Position repair clamp at side markings - arrow 1 - and -
arrow 3 - .
- Screw repair clamp - A - as depicted and tighten it to 25
Nm.
- Then align exhaust system free of tension 26-1,
Exhaust system, installing free of tension .
Exhaust system, installing free of tension
Align exhaust system when cold.
Exhaust system components Page 18 / 19
- Loosen bolts of front double clamp Item - 6 - .
- Push exhaust system far enough forward so that the pre-
tension at the retaining loop at rear muffler dimension - a -
= 15 to 17 mm.
- Install clamping sleeve so that the end of the bolt does
not extend beyond the lower edge of the clamping sleeve.
Threaded connection points towards right.
- Tighten clamping sleeve bolts uniformly to 25 Nm.
Tail pipes, aligning
- Align rear muffler so that distance - a - between bumper
Exhaust system components Page 19 / 19
cut-out and right and left tail pipes is equal.
At the same time, distance - b - of bumper cutout must run
parallel to tail pipes.
- To align tail pipes, loosen rear muffler mounting
components if necessary.
Secondary air injection (AIR) system Page 1 / 7
26 - 2
Secondary air injection (AIR) system
Caution!
When doing any repair work, especially in the engine
compartment, pay attention to the following due to
clearance issues:
Route lines of all types (e.g. for fuel, hydraulic,
EVAP canister system, coolant and refrigerant,
brake fluid, vacuum) and electrical wiring so that
the original path is followed.
To prevent damage to the lines, make sure there
is sufficient clearance to all moving or hot
components.
Secondary air injection (AIR) system, assembly overview
26-2, Secondary Air Injection (AIR) system, assembly
overview
Secondary Air Injection (AIR) Pump Motor V101 ,
removing and installing 26-2, Secondary Air Injection
(AIR) Pump Motor V101 , removing and installing .
Secondary Air Injection (AIR) valve, checking 26-2,
Secondary Air Injection (AIR) Solenoid Valve N112 ,
checking
Secondary Air Injection (AIR) system, assembly overview
Secondary air injection (AIR) system Page 2 / 7
10 Nm
Connecting pipe
Observe tightening
sequence 26-2,
Connecting tube - tightening
sequence
Connector
For Secondary Air Injection
(AIR) Solenoid Valve N112
Secondary air injection (AIR)
solenoid valve N112
Do not disassemble
Checking 26-2,
Secondary Air Injection (AIR)
Secondary air injection (AIR) system Page 3 / 7
Solenoid Valve N112 ,
checking
Pressure pipe
Ensure seated tightly
To disengage, squeeze
together securing ring
Bracket
Gasket
Allocation Electronic parts
catalog "ETKA"
10 Nm
Intake manifold
For secondary air injection
pump
Secondary air injection (AIR)
pump motor V101
Removing and installing
26-2, Secondary Air Injection
(AIR) Pump Motor V101 ,
removing and installing
Rubber bushing
25 Nm
10 Nm
Intake manifold support
With mount for Secondary
Air Injection (AIR) pump
motor V101
Intake tube
Cylinder head
Secondary air injection (AIR) system Page 4 / 7
Connecting tube - tightening sequence
- Replace all seals of connecting tube - A - .
- Install all bolts only hand-tight.
- Tighten bolts - 1 - first, then bolt - 2 - and lastly bolts - 3
- to 10 Nm.
Secondary Air Injection (AIR) Pump Motor V101 ,
removing and installing
Removing
- Remove noise insulation
Repair Manual, Body Exterior, Repair Group 50,
- Disconnect connectors - 1 - and - 2 - .
- Press out clip - 3 - for cable guide.
- Press out cable clip at top front mounting bolt.
Secondary air injection (AIR) system Page 5 / 7
- Disconnect pressure hose - 1 - and intake hose - 2 - .
To do so, compress securing ring.
- Remove mounting nuts and remove Secondary Air
Injection (AIR) Pump Motor V101 upward. When doing
this, press lower bolt (rubber bushing) slightly in order to
get by at transmission.
Installing
Installation is in reverse order of removal. Note the
following:
Make sure that pressure pipe and intake hose lock
securely to Secondary Air Injection (AIR) Pump
Motor V101 .
Tightening torque:
Component Nm
Secondary Air Injection (AIR) Pump Motor V101 to intake manifold support 10
Secondary Air Injection (AIR) Solenoid Valve N112 ,
checking
Special tools, testers and auxiliary items required
Secondary air injection (AIR) system Page 6 / 7
Connector test set V.A.G 1594C
Assisting hose, e.g. coolant hose
Work sequence
Note:
Do not use compressed air during following check!
- Remove engine cover with air filter 24-1, Engine cover
with air filter, removing and installing .
- Disconnect pressure hose - 2 - from Secondary Air
Injection (AIR) Solenoid Valve N112 - 3 - . To do so,
compress securing ring.
- Disconnect harness connector - 4 - .
- Slide assisting hose - 1 - , e.g. coolant hose, into
Secondary Air Injection (AIR) Solenoid Valve N112 .
- Blow forcefully into assisting hose - arrow - .
Valve must be closed.
If air can be blown through valve with assisting hose
properly sealed:
- Replace Secondary Air Injection (AIR) Solenoid Valve
N112 .
If valve is closed:
- Connect terminals on connector connection - 5 - with
adapter cables from connector test kit V.A.G 1594C to
battery positive (+) and negative (-).
- Blow forcefully into assisting hose - arrow - .
Secondary air injection (AIR) system Page 7 / 7
Valve must be opened.
If no air can be blown through valve with assisting hose
properly sealed:
- Replace Secondary Air Injection (AIR) Solenoid Valve
N112 .
