Volkswagen Golf/Jetta 2 manual

Exhaust system - inspection, removal and refitting
Fuel and exhaust systems - carburettor models / Exhaust system - inspection, removal and refitting


Inspection
1 Refer to Chapter 1, Section 19 Removal
2 On 1.6 and 1.8 litre engines, it should be noted that if the exhaust system is to be separated at the manifold/downpipe connection, then VW tool No. 3049A will be necessary to release and subsequently refit the joint retaining clips (see illustration).

Without this tool, it is virtually impossible to separate and reassemble the joint without distorting the retaining clips. In view of this, removal and refitting of the system will necessitate detachment of the manifold and front pipe section, or manifold and system complete, and then taking the assembly to your VW dealer to separate/reassemble the front joint. If the complete system is in need of replacement, it is probably best entrusted to your VW dealer.

20.2 VW tool 3049A used to release and fit exhaust downpipes to manifold
20.2 VW tool 3049A used to release and fit exhaust downpipes to manifold clips - 1.6 and 1.8 litre

3 On 1.05 and 1.3 litre engines, when removing any part of the exhaust system it is usually easier to undo the manifold-to-front pipe joint and remove the complete system from the vehicle, then separate the various pieces of the system, or cut out the defective part with a hacksaw.

4 Before doing any dismantling work on the exhaust system, wait until the system is cool and then saturate all bolts and joints with a proprietary anti-corrosion fluid (see illustrations). It may be found easier to cut through heavily corroded bolts with a hacksaw, rather than try to unscrew them.

20.4a Exhaust system and associated components Ц 1.5 and 1.3 litre
20.4a Exhaust system and associated components Ц 1.5 and 1.3 litre

20.4b Exhaust system and associated components Ц 1.6 and 1.8 litre
20.4b Exhaust system and associated components Ц 1.6 and 1.8 litre

Refitting
5 Refit the system a section at a time starting at the front. If the manifold has been removed its gasket must be renewed. New nuts and bolts should be used throughout the system.

6 Before assembly, smear all joints with a proprietary exhaust sealing compound. This makes it easier to align the pieces and also ensures that the joints will be gas tight. Leave all bolts loose.

7 Run the engine until the exhaust system is at normal temperature and then, with the engine running at idling speed, tighten all the mounting bolts and clips, starting at the manifold and working towards the rear silencer. Take care to avoid touching any part of the system with bare hands because of the danger of painful burns.

8 With all bolts and clips tightened, it is important to ensure that there is no strain on any part of the system.


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