If it is difficult to disconnect the exhaust pipes, use one of the following methods.
1. Cut the exhaust pipe 5 cm behind the double clamp. Saw the remaining piece of pipe along the axis and, using a hammer and chisel, knock it down
2. Using an oxyfuel welder, heat up the pipe joint and separate the pipes.
Withdrawal
Position the vehicle above a pit or on a lift.
Cut the pipe connecting the rear and middle mufflers.
Front-wheel drive vehicles with 1.9-I-TDI 110 hp diesel engines.
The pipe cutting point is located at a distance of 160-180 mm from the rear muffler (see fig. 4D.15).
Front wheel drive vehicles with V6 engines
The pipe cut point is 182 mm from the rear muffler (see fig. 4D.16).
4x4 vehicles
The pipe cutting point is 244 mm from the middle muffler (see fig. 4D.17).
Release the muffler from the rubber suspension pads and remove it from under the car.
Installation
Install the muffler and secure it to the rubber suspension pads.
Connect the pipes with a double clamp. Keep in mind that exhaust system pipes have different diameters, so use a clamp of the correct size.
Vehicles with 125 hp engine
Connect the pipes of the middle and rear mufflers with a double clamp, positioning it in such a way that the bolt head is on the side of the fuel tank, and the connecting plane of the clamp clips should be at an angle of 30°to the vertical plane (see fig. 4D.18).
Front wheel drive vehicles with engines other than 125 hp
Connect the pipes of the rear and middle mufflers with a double clamp, positioning it so that the lower edge of the clamp mounting bolt is at the level of the muffler pipe (see fig. 4D.11). The bolts should be located on the left side of the pipe.
4x4 vehicles
Connect the pipes of the rear and middle mufflers with double clamps, positioning them so that the lower edge of the clamp bolts is located at the level of the muffler pipe (see fig. 4D.19). The bolts must be on the inside.
Align the elements of the exhaust system and check that the system is installed freely, without tension and that the gap from the body elements must be at least 25 mm. Tighten the double clamp bolts to 40 Nm.
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