Exhaust pipes and silencers

1.1 Assembly overview - silencers

• 1 Exhaust pipe with rear silencer
  • Coupling point
  • Marked by indentation on exhaust pipe.
  • As standard, exhaust pipe and rear silencer are installed as a single component. For repairs, exhaust pipe and silencer are supplied with a clamp separately If the rear silencer is to be replaced ⇒ 26 – Exhaust system.
• 2 Retaining ring
  • 23 Nm
  • Renew if damaged
• 3 20 Nm
• 4 Tunnel cross-piece

1.2 Separating exhaust pipes from silencers

Special tools and workshop equipment required

• Body saw e.g. -V.A.G 1523 A-
• Or

• Chain-type pipe cutter - VAS 6254-
• Safety glasses

Procedure

To separate exhaust pipe and silence, exhaust pipe is engineered with a separation point marked by indentations.

• Cut through exhaust pipe at right angles using body saw at separating point -arrow 1-.
• Position double clamp -4- on side markings -arrow 2- and -arrow 3- when installing.

• Install double clamp so that bolt ends do not protrude beyond bottom of clamp.

• Bolt connections point to the right.

• Tighten bolt connections of double clamps evenly to 23 Nm.

Before tightening, align cold exhaust system free of stress ⇒ 1.2 Separating exhaust pipes from silencers.

1.3 Aligning exhaust system free of stress

Special tools and workshop equipment required

• Torque wrench - V.A.G 1331-

Condition

• The exhaust system is cold.

Procedure

• Loosen threaded connections of the front clamp.
• Align clamp on front exhaust pipe under consideration of dimension -a-. Dimension -a- = 5 mm

• Align clamp so that bolt ends do not protrude beyond lower edge of clamp -arrow-.
• Tighten front threaded connection of clamp slightly.

• Then align exhaust system with mountings under consideration of dimension -a-. -Arrow- points in direction of travel. Dimension -a- = 3 … 7 mm.

• Then evenly tighten securing nuts -arrows- of foremost clamp. Specified torque: M8 = 25 Nm, M10 = 40 Nm.
• Once clamp has been tightened, check set-up dimensions and correct if necessary.

1.4 Installation position of clamp

Installation position of clamp

• Position double clamp at distance -a- = 5 mm from marking on front exhaust pipe.

• Install double clamp so that bolt ends do not protrude beyond bottom of clamp.

• Bolt connections point to the right.

• Tighten bolt connections of double clamps evenly to 23 Nm.

Before tightening, align cold exhaust system free of stress ⇒ 1.2 Separating exhaust pipes from silencers.