Volkswagen Workshop Service and Repair Manuals

Front exhaust pipe and catalyst with attachments
Engine codes:

• ◆ 1Z, AHU, AFN
• ◆ AAZ => Page 26-3

Silencer with mountings
Engine codes:

• ◆ 1Z, AHU, AFN => Page 26-4
• ◆ AAZ => Page 26-8

Notes:

• ◆ Removing and installing exhaust manifold , Removing and installing turbocharger with attachments.
• ◆ After working on the exhaust system ensure that the system is not under stress, and that it has sufficient clearance from the bodywork. If necessary, loosen double and single clamps and align silencer and exhaust pipe so that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded.
• ◆ Renew self-locking nuts.

Front exhaust pipe and catalyst with attachments

Engine codes 1Z, AHU, AFN

• From turbocharger
• Gasket
• ◆ Renew
• 25 Nm
• Front exhaust pipe
• Sealing ring
• ◆ Renew if damaged
• Catalyst
• To intermediate pipe
• ◆ => Page 26-4 , Item 4

Engine code AAZ

• From turbocharger
• Gasket
• ◆ Renew
• 25 Nm
• Front exhaust pipe
• Sealing ring
• ◆ Renew if damaged
• Catalyst
• To intermediate pipe
• ◆  , Item 4
• Retainer
• ◆ Between exhaust pipe and exhaust manifold

Silencer with mountings

Engine codes 1Z, AHU, AFN

Note:

Align the exhaust system longitudinally so that the dimensions -a- and -b- are maintained.

• From catalyst
• 40 Nm
• Double clamp
• Intermediate pipe
• Clamp
• Console
• Mounting
• 25 Nm
• Rear silencer

• Marking
• ◆ For clamp
• ◆ Three times on circumference
• ◆ Distance clamp/marking => Item 14
• Separating point
• ◆ For repair cases
• ◆ When replacing central silencer
• ◆ Marked by three impressions on circumference of connecting pipe
• ◆ Central and rear silencer are installed as one part as standard. In repair cases the central and rear silencer are supplied individually and a repair connecting pipe with two clamps supplied as joint.
• ◆ Cut through connecting pipe with body saw e.g. V.A.G 1523 at right angles at the separating point.

• Separating point
• ◆ For repair cases
• ◆ When replacing rear silencer
• ◆ Marked by three impressions on circumference of connecting pipe
• ◆ Central and rear silencer are installed as one part as standard. In repair cases the central and rear silencer are supplied individually and a repair connecting pipe with two clamps supplied as joint.
• ◆ Cut through connecting pipe with body saw e.g. V.A.G 1523 at right angles at the separating point.
• Dimension -b- = approx. 10 mm
• Dimension-a- = ca. 5 mm

• Marking
• ◆ Three times on circumference
• Marking
• ◆ Three times on circumference
• ◆ S = Manual gearbox
  A = Auto. gearbox
• Repair connecting pipe
• Centre silencer

Engine code AAZ

Note:

Align the exhaust system longitudinally so that the dimensions -a- and -b- are maintained.

• From catalyst
• 40 Nm
• Double clamp
• Intermediate pipe
• Clamp
• Console
• Mounting
• 25 Nm
• Rear silencer

• Marking
• ◆ For clamp
• ◆ Three times on circumference
• ◆ Distance clamp/marking => Item 14
• Separating point
• ◆ For repair cases
• ◆ When replacing central silencer
• ◆ Marked by three impressions on circumference of connecting pipe
• ◆ Central and rear silencer are installed as one part as standard. In repair cases the central and rear silencer are supplied individually and a repair connecting pipe with two clamps supplied as joint.
• ◆ Cut through connecting pipe with body saw e.g. V.A.G 1523 at right angles at the separating point.

• Separating point
• ◆ For repair cases
• ◆ When replacing rear silencer
• ◆ Marked by three impressions on circumference of connecting pipe
• ◆ Central and rear silencer are installed as one part as standard. In repair cases the central and rear silencer are supplied individually and a repair connecting pipe with two clamps supplied as joint.
• ◆ Cut through connecting pipe with body saw e.g. V.A.G 1523 at right angles at the separating point.
• Dimension -b- = approx. 10 mm
• Dimension-a- = ca. 5 mm

• Marking
• ◆ Three times on circumference
• Marking
• ◆ Three times on circumference
• ◆ S = Manual gearbox
  A = Auto. gearbox
• Repair connecting pipe
• Centre silencer