REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Golf IV (1997 release)

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Volkswagen
	Golf 4
		Instructions
		Engine
		Cooling system
		Fuel System
		Exhaust system
			Catalyst
			Removing and installing exhaust system
			Alignment exhaust system
			Replacing the middle / rear silencer
			Removal and installation of a silencer
			Removing and installing Lambda probe
		Ventilation and heating system
		Coupling
		Transmission
		Suspension brackets and power shafts
		Steering
		Wheels and tires
		Brakes
		Body
		Electrical equipment and wiring

printable version

Removing and installing exhaust system

Turbochargers cars with engines AHF and ALH

1 - exhaust manifold;
2 - the inlet manifold;
3 - from the radiator nadduvaemogo air;
4 - seal. When installing a new seal must be used;
5 - a bolt; 25 Nm;
6 - seal. Observe installation position of sealing;
7 - an arm;
8 - a washer;
9 - the screen;
10 - turbocharger. When removing the turbocharger you must first remove the right drive shaft;
11 - box pressure;
12 - from the air filter;

13 - seal. When installing a new seal must be used;
14 - a sealing ring. When installing, use a new sealing ring;
15 - oil supply line;
16 - a hollow bolt, 40 Nm;
17 - a bolt, 15 Nm;
18 - a bolt, 40 Nm;
19 - an arm;
20 - a bolt, 25 Nm;
21 - seal. When installing a new seal must be used;
22 - a reception exhaust pipe;
23 - Connecting fittings;
24 - a bolt, 10 Nm;
25 - oil return pipe

Sequence of a tightening of bolts of fastening of a reception exhaust pipe to the exhaust manifold on the engine without a turbocharger

Withdrawal

The exhaust system can be removed as a complete and separate sections.

PERFORMANCE ORDER

1. Lift the car and fix it on supports. Remove the bottom mudguard of a motor compartment.
2. Put on the nuts and bolts securing the elements of the exhaust system means destroying rust. Wait a while until the rust will not be destroyed completely.
	3. Remove the casing that covers the electric connector Lambda sensor (two lower arrows).
4. Release the lambda sensor wire from clips on thermofilter screen (upper arrow).
5. Disconnect the electric connector Lambda sensor.
6. On all-wheel drive models and models with engine 1,6-I with an automatic transmission Lambda sensor is installed in the exhaust manifold and is not required to disconnect the electrical connector Lambda sensor.
7. On models with engines 1,4-I lambda sensor is mounted near the front of the gasket flange reception exhaust pipe.
	8. Bottom unscrew a reception exhaust pipe from the exhaust manifold (nuts are specified by arrows).
9. Support the exhaust system, it tied up with wire to the bottom of the car.
10. Remove the front part of the exhaust system on the front crossbar.
11. Loosen the clamps and remove the exhaust system.

Setting

PERFORMANCE ORDER

1. In order to facilitate the subsequent loosening nuts and bolts securing the exhaust system, lubricate them with high-temperature paste Liqui Moly LM-508-ASC.
2. Before re-connection of the exhaust system components, clean them with sandpaper connection from the remnants of sealant and rust.
	3. Secure holders exhaust system to the front cross beam so that the sloped side (arrows) towards the front of the vehicle.
4. Insert the exhaust system into the rubber cushions.
5. Tighten the holders of the exhaust system to the front frame 25 Nm.
Engines without turbocharger
6. Connect a reception exhaust pipe with a new gasket to the exhaust manifold and tighten the bolts in the sequence shown in fig. Sequence of a tightening of bolts of fastening of a reception exhaust pipe to the exhaust manifold on the engine without a turbocharger 40 Nm.
Engines with a turbocharger
7. Connect the reception exhaust pipe with a new gasket to turbocharger and tighten the bolts crosswise to 40 Nm.
8. If necessary, turn the section of the exhaust system so that the entire exhaust system was located at the same distance from the body.
9. Finally, tighten all nuts and bolts securing the exhaust system.
10. Establish the bottom mudguard of a motor compartment.
11. Secure the lambda sensor spring clips. Connect the electrical connector Lambda sensor and close the cover.
12. Start the engine and check the tightness of the exhaust system.

The tightening moments

Exhaust manifold to cylinder head	25 Nm
The clamps securing the connection of exhaust pipes	40 Nm
Reception exhaust pipe to a collector	40 Nm
Mount exhaust pipe branching exhaust system	25 Nm
Lambda sensor catalyst	50 Nm

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Alignment exhaust system