Volkswagen Golf / Golf Plus. Manual - part 338

Installation position of rear clamp (repair double clamp)
– Install clamp so that ends of bolts do not protrude beyond bot‐

tom of clamp.

• Bolt connection faces to left.

1.3.1

Separating front and rear silencers

Special tools and workshop equipment required
♦ Pneumatic sabre saw -V.A.G 1523 A-

♦ Eye protection
Procedure

WARNING

Wear eye protection.

– Cut exhaust pipe at right angles at separating point

-arrow 2-.

– When installing, position repair double clamp -4- at side mark‐

ings -arrow 1- and -arrow 3-.

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     Rep. Gr.26 - Exhaust system

 

• Bolted connection faces rear.
– Align cold exhaust system free of stress 

⇒ page 192

 .

– Tighten bolts on repair double clamp.
Specified torque, M8: 25 Nm
Specified torque, M10: 40 Nm

1.4

Assembly overview - silencer with mountings (vehicles with four-wheel

drive)

1 - From particulate filter
2 - Clamp

❑ Align exhaust system

free of stress before

tightening clamp

⇒ page 192

 .

❑ Installation position

⇒ page 192

❑ Tighten threaded con‐

nections evenly.

3 - Bracket

❑ For retaining ring

4 - 25 Nm
5 - Retaining ring

❑ Renew if damaged.

6 - Rear silencer
7 - Mounting

❑ Renew if damaged.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1. Exhaust system    

191

 

1.5

Aligning exhaust system free of stress

Prerequisite
• Engine must be cold
Procedure
– Loosen bolted connection of clamp between front exhaust

pipe and silencer.

– Position clamp at distance -a- = 5 mm from marking on front

exhaust pipe and lightly tighten front bolted connection.

– Push exhaust pipe with silencer forwards into clamp until di‐

mension -a- 15...17 mm is attained between mounting attach‐

ment points for body and rear silencer. -Arrow- points in

direction of travel.

– Align rear silencer horizontally.
– With parts in this position, tighten bolted connections of clamp.
Specified torque, M8: 25 Nm
Specified torque, M10: 40 Nm
– Once clamp has been tightened, check distance -a- and cor‐

rect if necessary.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

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     Rep. Gr.26 - Exhaust system

 

2.1

Assembly overview - parts of exhaust

gas recirculation

Engine codes BKC, BRU, BXE and BXF 

⇒ page 193

Engine code BJB 

⇒ page 195

Engine codes BLS and BXJ 

⇒ page 196

2.1.1

Engine codes BKC, BRU, BXE and BXF

Note

♦

The exhaust gas recirculation system is activated by the diesel

direct injection system control unit -J248- via exhaust gas re‐

circulation valve -N18- (electric-pneumatic) to the exhaust gas

recirculation valve (mechanical).

♦

The electro-pneumatic exhaust gas recirculation valve -N18-

is located in the solenoid valve block.

♦

The cone-shaped plunger in the mechanical exhaust gas re‐

circulation valve ensures that various cross sectional openings

are possible at different plunger lifts.

♦

Pulsed control enables every conceivable valve position.

♦

Renew self-locking nuts.

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2. Exhaust gas recirculation system    

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