Volkswagen Golf Variant / Jetta. Manual - part 450

Vehicles with Engine Code CJAA

1 - Mounting Strap

❑ For the fuel tank

-item 10-

⇒ Item 10 (page 231)

2 - Mount

❑ Replace if damaged

3 -

❑ 23 Nm
❑ Replace

4 - Retaining Loop

❑ Replace if damaged

5 - Exhaust Pipe
6 - Bolt

❑ 23 Nm

7 - Mount

❑ Replace if damaged

8 - Rear Muffler

❑ For repairs, replace

each separately

❑ Exhaust System, Sepa‐

rating and Connecting.

Refer to

⇒ “1.8 Exhaust System,

Disconnecting and Con‐

necting”, page 384

 .

❑ Align the exhaust sys‐

tem free of stress. Refer

to

⇒ “1.9 Exhaust System,

Installing without Ten‐

sion”, page 385

 .

❑ Exhaust System,

Checking for Leaks. Refer to 

⇒ “1.10 Exhaust System, Checking for Leaks”, page 387

 .

9 - Nut

❑ 23 Nm

10 - Repair Clamping Sleeve

❑ For individual replacement of exhaust pipe and rear mufflers
❑ Note the installation position Refer to

⇒ Fig. ““Repair Clamping Sleeve Installation Position”“ , page 384

 .

❑ Exhaust System, Separating and Connecting. Refer to

⇒ “1.8 Exhaust System, Disconnecting and Connecting”, page 384

 .

❑ Align the exhaust system free of stress. Refer to

⇒ “1.9 Exhaust System, Installing without Tension”, page 385

 .

❑ Tighten the bolted connections evenly

11 - Tunnel Brace

1. Exhaust System    

383

-arrow- does not project beyond the lower edge of clamping

sleeve:

• Threaded connection points toward the right.
• Tighten the threaded connections equally to 23 Nm.

1.8

Exhaust System, Disconnecting and

Connecting

Note

♦

A separating point has been provided in the connecting pipe

for removing, installing and individual replacement of the cen‐

ter or rear muffler.

♦

The separating point is marked an indentation around the cir‐

cumference of the exhaust pipe.

Special tools and workshop equipment required
♦ Pneumatic Body Saw - VAS6780- or
♦ Chain Pipe Cutter - VAS6254-
♦ Torque Wrench 1331 5-50Nm - VAG1331- (not illustrated)
♦ Protective Eyewear
♦ Protective clothing
Conditions
• Engine must be cold.
Procedure

WARNING

To prevent injuries from metal shavings, wear protective gog‐

gles and protective clothing.

– Cut the exhaust pipe at a right angle at the separating point

-arrow 2-, for example using a Pneumatic Body Saw -

VAS6780- or Chain Pipe Cutter - VAS6254- .

Connecting:
– Position the repair clamping sleeve at the side marks

-arrow 1 and 3- for installation.

384

-arrow- does not project beyond the lower edge of clamping

sleeve:

• Threaded connection points toward the right.
• Tighten the threaded connections evenly.
• Tightening specification: 23 Nm.

Aligning Tail Pipes
– Align rear muffler so that the distance -a- between bumper cut-

out and tail pipes is uniform on left and right.

1.9

Exhaust System, Installing without Ten‐

sion

Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
Conditions
• Engine must be cold.
Procedure
– Loosen the threaded connections -3 and 4- on the clamping

sleeve -1- between the slip catalyst -2- and the front muffler

(the -arrow- points in the direction of travel).

– Align the clamping sleeve -1- to the marking -A- on the slip

catalyst -2-.

• Dimension -a- = 5 mm

1. Exhaust System    

385

yond the lower edge of the clamping sleeve -arrow-.

– Tighten the front connection -3- on the clamping sleeve -1- by

hand.

– Push the exhaust system as far as possible forward into the

double clamp until dimension -a- is reached on the retaining

loop (-arrow- points in direction of travel).

• Dimension -a- 15 to 17 mm.

– In this position, tighten the connections -3 and 4- on the clamp‐

ing sleeve -1- evenly.

• Tightening specification -item 8- 

⇒ Item 8 (page 377)

 .

– After tightening the clamping sleeve, check dimension -a- and

correct if necessary.

386