Volkswagen Golf Variant / Jetta. Manual - part 453

 

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Volkswagen Golf Variant / Jetta. Manual - part 453

 

 

Installing

Caution

There is a risk of damaging the decoupling element between

the  particulate  filter  and  NOx  reduction  catalytic  converter.

When removing and installing:

♦ Do not bend the decoupling element more than 10°.
♦ Do not stretch the decoupling element.
♦ Do not damage the wire mesh on the decoupling element.
♦ Use the Transportation Lock - T10404- to secure the de‐

coupling element from stretching.

– Mount the particulate filter bracket on the crankcase and install

the nuts by hand.

– Mount the particulate filter on the bracket.
– Secure the exhaust pipe to the driveshaft or to the body.
– Install the screw on the particulate filter bracket by hand.
– Slide the double clamp into position on the exhaust pipe.
– Guide the temperature sensor wires upward.
– Position the clamp on the turbocharger and tighten it.
– Tighten the screws in the following sequence:
1.

Lower particulate filter bracket to crankcase.

2.

Particulate filter to lower particulate filter bracket, use the

Wrench - Sw13 - T10384- .

3.

Particulate filter to upper particulate filter bracket

– Install the axle shaft heat shield with Hex Ball Socket - 3247- .
– Mount the right axle shaft joint on the bevel box. Refer to ⇒ 

Suspension, Wheels, Steering; Rep. Gr.  40 .

– Install the subframe with the steering gear. Refer to ⇒  Sus‐

with Hydraulic Steering Gear, Removing and Installing .

– Install the suspended mounting for the exhaust pipe to the

subframe.

– Tighten the double clamp on the exhaust system.

2.3

Overview - Muffler

Exhaust Pipe, Disconnecting. Refer to

⇒ “2.4 Exhaust Pipe, Disconnecting”, page 396

 .

2. Exhaust System, Engine Codes CBDA, CBDB and CEGA    

395

❑ Replace

2 - Retaining Ring

❑ Replace if damaged

3 - Rear Muffler
4 - Mount

❑ Replace if damaged

5 - 25 Nm
6 - Tunnel Brace

2.4

Exhaust Pipe, Disconnecting

Special tools and workshop equipment required
♦ Pneumatic Body Saw - VAS6780-

396

point -A-.

– During installation, position the repair double clamp at side

markings -B- .

Tightening specification:
♦ M8 = 25 Nm
♦ M10 = 40 Nm

2.5

Exhaust System, Installing without Ten‐

sion

• Engine must be cold.
– Loosen the double clamp threaded connection between the

catalytic converter and the front muffler.

– Position the double clamp at a distance -a- = 5 mm from the

marking on the catalytic converter pipe and gently tighten the

front threaded connection.

– Push the rear muffler as far forward into the double clamp until

dimension -a- reaches 15-17 mm between the suspended

mount/body and the suspended mount/rear muffler.

The -arrow- points in the direction of travel.
– Align rear muffler horizontally.
– Tighten the threaded connections of the double clamp in this

position. Tightening specification: 25 Nm.

– After tightening the double clamp, check dimension -a- and

correct if necessary.

2. Exhaust System, Engine Codes CBDA, CBDB and CEGA    

397

EGR System

⇒ “3.1 Overview - Exhaust Gas Recirculation System Compo‐

nents”, page 398
⇒ “3.2  EGR Temperature Sensor G98 , Removing and Installing”,

page 399

3.1

Overview - Exhaust Gas Recirculation

System Components

Special tools and workshop equipment required
♦ Hose Clip Pliers - VAS6362-

Note

Always replace the self-locking nuts, seals, gaskets and se‐

curing clamps. Refer to Parts Catalog.

Hoses are secured with spring clips.

Hose Clip Pliers - VAS6362- or the Hose Clip Pliers -

VAS6340- are recommended for installing spring clips.

1 - Seal

❑ Replace
❑ Note the installation po‐

sition

2 - Connecting Pipe

❑ For removing and instal‐

ling, also loosen the

connections -item 33-

⇒ Item 33 (page 273)

 on

the turbocharger

3 - To the Connection on the

Turbocharger

❑ -item 33-

⇒ Item 33 (page 273)

4 - Seal

❑ Replace if damaged

5 - Bolt

❑ 8 Nm

6 - Radiator

❑ For the EGR

7 - Nut

❑ 23 Nm
❑ Installed on the hex stud

bolt -item 17-

⇒ Item 17 (page 272)

 on

the turbocharger

8 - Control Line

❑ 23 Nm
❑ Do not change the an‐

gles of the control line

❑ To the Exhaust Pres‐

398

 

 

 

 

 

 

 

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