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26-1

Exhaust system components,


removing and installing
WARNING!

Observe the following for all installations,


especially in engine compartment due to lack
of room:

Route lines of all types (e.g. for fuel,


hydraulic, EVAP canister system, coolant
and refrigerant, brake fluid, vacuum) and
electrical wiring so that the original path is
followed.

Watch for sufficient clearance to all moving


or hot components.

Notes:

After exhaust system repairs, make sure


exhaust system is not under stress and that it
has sufficient clearance from the bodywork. If
necessary, loosen double clamps and clamp
and align exhaust pipe so that sufficient
clearance is maintained to the bodywork and
support rings carry uniform loads.
Always replace self-locking nuts.
26-2

1 - 30 Nm
Always replace
Coat threads with G 052 112 A3
2 - Exhaust manifold
with turbocharger Page 21-1 , Turbocharger with
attachments, removing and installing
3 - Gasket
Always replace
4 - Heated Oxygen Sensor (HO2S) -G39- before
catalytic converter, 50 Nm
Only use "G 052 112 A3" to grease thread; do not let
"G 052 112 A3" get onto slit of oxygen sensor
Use 3337 to remove and install
Checking:

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel Injection &


Ignition, Engine Code(s): ATW, AUG, AWM, Repair Group
24; Checking Function; Oxygen sensor and oxygen sensor
control before catalytic converter, checking

5 - Catalytic converter
Checking Page 26-8
26-3

6 - Oxygen Sensor (O2S) Behind Three Way Catalytic


Converter (TWC) -G130-
Only use "G 052 112 A3" to grease thread; do not let
"G 052 112 A3" get onto slit of oxygen sensor
Use 3337 to remove and install
Checking:

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel Injection &


Ignition, Engine Code(s): ATW, AUG, AWM, Repair Group
24; Checking Function; Oxygen sensor and oxygen sensor
control behind catalytic converter, checking

7 - 25 Nm
Always replace
Coat threads with G 052 112 A3
8 - Marking
3x at perimeter
Slide double clamp -item no. 21 - up to marking on
tube
9 - Support ring
With retainer ring
10 - Support ring
11 - 25 Nm
26-4

12 - Rear muffler
At factory, center and rear mufflers are installed as a
single component. Replacement center and rear
mufflers are supplied separately, with double clamp
for connecting joint.
Removing and installing:
- Using VAG 1523 Chassis saw, cut at right angle
through connecting pipe at separation point - 18 -.
13 - Dimension -a- approx. 7 to 9 mm
Exhaust system must be cold
Arrow shows direction of travel
To adjust exhaust system, slide double clamp - 21 -
onto exhaust pipe up to marking - 8 - and tighten
slightly Slide center and rear mufflers far enough
forward that dimension -a- is obtained. Tighten
double clamp.
26-5

14 - Bolt head must face fuel tank


15 - Angle - - = 30 5
16 - Bolt end must not be below double clamp
Double clamp viewed in direction of travel
17 - Angle - - = 10 + 5
18 - Separating point
approx. 160 to 180 mm in front of rear muffler,
marked by a recess in the pipe.
19 - Double clamp
Tighten evenly to 40 Nm
20 - Center muffler
21 - Double clamp
Tighten evenly to 40 Nm
26-6

22 - Decoupling element
max. flex 10
23 - Support ring
Individual components Fig. 1
24 - Front exhaust pipe
25 - 30 Nm
Always replace
Coat threads with G 052 112 A3
26 - Washer
26-7

Fig. 1 Individual components of suspension


1 - Strap with buffer
2 - Exhaust pipe
3 - Washer
4 - Hex bolt, 25 Nm
5 - Self-locking nut, 25 Nm
6 - Spacer sleeve
7 - Compression spring
8 - Hex bolt
26-8

Three Way Catalytic Converter (TWC),


checking

Special tools and equipment

VAG 1551 Scan tool (or VAG 1552 Mobile scan


tool) with VAG 1551/3 Cable

VAG 1788/10 RPM adjuster

Test sequence

- Connect VAG 1551 Scan tool (or VAG 1552). Start engine and select the Engine
Control Module (ECM) using address word 01. Connecting scan tool and
selecting Engine Control Module (ECM):

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel Injection & Ignition, Engine Code
(s): ATW, AUG, AWM, Repair Group 01; General information for On Board
Diagnostic (OBD); connecting Scan Tool (ST)

Rapid data transfer HELP Indicated on display:


Select function XX
- Press buttons -0- and -4- to select "Basic Setting" function 04. Press -Q- button
to confirm input.

Basic setting Indicated on display:


Enter display group number XXX
- Use VAG 1788/10 RPM Adjuster to adjust engine RPM to between 2300 and
2500 RPM:
26-9

- Press buttons -0-, -3- and -4- to select "Display


group number 34". Press -Q- button to confirm
input.

System in basic setting 34 Indicated on display: (1 to 4 display fields)


1 2 3 4
- Maintain engine speed until indication in display field 4 jumps from "Test OFF" to
"Test ON". The catalytic converter temperature in display field 2 must be at least
350 C.
- Continue to maintain engine speed until display field 4 indicates specified value
"B1-S1 OK".
- Press -C- button.
- Press buttons -0-, -4- and -6- to select "Display group number 46". Press -Q-
button to confirm input.

Basic setting 46 Indicated on display: (1 to 4 display fields)


1 2 3 4
- Maintain engine speed until indication in display field 4 jumps from "Test OFF" to
"Test ON".

The catalytic converter temperature in display field 2 must be at least 430 C for
engines AUG; and at least 550 C for engine AWM.
26-10

Engine code AUG

- Check amplitude ratio in display field 3:

Specification: max: 0.4

Engine code AWM

- Check diagnostic value in display field 3:

Specification: MIN: 1.0

Continuation for all

- Continue to maintain engine speed until display


field 4 indicates specified value "Cat-B1 OK".

If display field 4 indicates "Cat B1 not OK":

- Check DTC memory:

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel


Injection & Ignition, Engine Code(s): ATW, AUG,
AWM, Repair Group 01, DTC memory; Engine
Control Module (ECM) DTC memory, checking
and erasing

If specified value "Cat B1 OK" is obtained:

- Press -button.

Rapid data transfer HELP Indicated on display:


Select function XX
- Press buttons -0- and -6- to select "End data transfer" function 06. Press -Q-
button to confirm input.