Volkswagen Workshop Service and Repair Manuals > Golf Mk5 > Power unit | 4-cylinder injection engine (1.6 l roller rocker finger) | Exhaust system | Exhaust system, engine codes BGU, BSE, BSF, CCSA

Removing and installing exhaust manifold

Removing

–	Remove front exhaust pipe together with catalytic converter → Chapter.

–	Remove intake manifold → Chapter.

–	Remove electrical connector -arrow- for Lambda probe -G39- before catalytic converter from retainer and separate.

Engine code BGU

–	Disconnect cable clamp -2-.

–	Loosen union nut -1-.

–	Remove nuts -3- and remove connecting pipe for exhaust gas recirculation.

Continuation for all vehicles

–	Remove nuts -1- for heat shield -3- and remove washers -2-.

–	Remove nuts -8- for both brackets -4- and remove washers -7-.

–	Remove remaining nuts from exhaust manifold -6- and remove washers.

–	Remove exhaust manifold and exhaust manifold gasket -5-.

Installing

Installation is carried out in the reverse order. When installing, note the following:

Note

Renew seals, gaskets and self-locking nuts.

–	Install intake manifold → Chapter.

–	Install front exhaust pipe together with catalytic converter → Chapter.

–	Align exhaust system free of tension → Chapter.

Torque settings

Component		Nm
Exhaust manifold to cylinder head		25 → Note
Heat shield to exhaust manifold		23
Connecting pipe for exhaust gas recirculation to exhaust gas recirculation valve (engine code BGU only)		23
Connecting pipe for exhaust gas recirculation to exhaust manifold (only engine code BGU)		60

¹⁾	Renew self-locking nuts.

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