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Volkswagen Passat B5 (from 1996 to 2004, the year of issue)

general info. full specifications. diagnostics. hints. tips. tricks
Volkswagen Passat B5
Passat B5
Fuel system
Motor Control
An exhaust system
general information
Operation of cars with catalytic converter
Replacement silencing
The oxygen sensor
Heating, ventilation

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An exhaust system

Exhaust system with front-wheel drive four-and five-cylinder petrol engines

A warning

The figure shows the exhaust system of the car with the engine 1,8-I ADR.

1 - a nut, 25 Nm
2 - the exhaust manifold,
3 - the oxygen sensor, 50 Nm
4 - a lining,
5 - a reception exhaust pipe,
6 - a nut, 30 Nm
7 - a nut, 25 Nm
8 - catalyst
9 - a collar,
10 - theft,
11 - a bolt, 25 Nm
12 - additional silencer
13 - Size A = 7-9 mm
14 - the place of the exhaust pipe,
15 - central silencer
16 - clip 40 Nm
17 - the place of the exhaust pipe,
18 - central silencer
19 - suspension,
20 - a reception exhaust pipe,
21 - catalyst
22 - Washer

The exhaust system is front-wheel drive with a diesel engine

1 - the additional muffler,
2 - the central silencer
3 - suspension,
4 - a bolt, 25 Nm
5 - suspension,
6 - clip 40 Nm
7 - an intermediate pipe
8 - a nut, 25 Nm
9 - turbocharger,
10 - Laying,
11 - catalyst
12 - a bolt, 25 Nm
13 - Laying,
14 - a nut, 25 Nm

Exhaust manifolds and intake exhaust pipes of cars with engines 6V (rest of the exhaust system is the same as that of the all-wheel drive cars)

1 - bush
2 - a bolt,
3 - a washer,
4 - an arm,
5 - sleeve,
6 - grommet,
7 - a nut, 25 Nm
8 - spring
9 - a bolt, 25 Nm
10 - to the central portion of the exhaust system,
11 - left a reception exhaust pipe with catalytic converter,
12 - the oxygen sensor number 2, 50 Nm
13 - Black uses a four electric socket,
14 - a nut, 25 Nm
15 - cap, 10 Nm
16 - a branch pipe,
17 - upper thermofilter,
18 - lower thermofilter,
19 - Left exhaust manifold,
20 - Laying,
21 - Right exhaust manifold,
22 - the oxygen sensor number 1, 50 Nm
23 - Right reception pipe with catalytic converter

Central and rear part of the exhaust system on the four-wheel drive vehicles with four- and five-cylinder engines

1 - a bolt, 25 Nm
2 - suspension,
3 - a nut, 40 Nm
4 - button head screw,
5 - clip 40 Nm
6 - the connection pipes of the exhaust system,
7 - right silencer,
8 - suspension,
9 - bracket
10 - the left silencer,
11 - the intermediate exhaust pipe,
12 - Laying,
13 - catalyst
14 - turbocharger,
15 - clip 40 Nm
16 - Central Silencer

Elements of the bracket to support the reception of the exhaust pipe

1 - a buffer
2 - sleeve,
3 - a washer,
4 - left pad,
5 - a washer,
6 - bolt,
7 - sleeve,
8 - right pad,
9 - a spring,
10 - a bolt,
11 - Self-locking nut, 25 Nm

The distance (a) by which to shift the exhaust system during the installation

a = 7 - 9 mm.

The arrow indicates the direction of movement of the car.

The exhaust system consists of exhaust manifold, turbocharger, a reception exhaust pipe, the central and additional mufflers.

In vehicles with V6 engines installed two separate exhaust system.

On vehicles with all-wheel drive set the double rear muffler.

Connection elements of the exhaust system is screwed or clamp.

The objective is to exhaust system exhaust to the atmosphere so that they are even in a minimal amount not included in the interior of the vehicle, as well as reducing engine noise to a low level. To exhaust system to perform its functions, it must be in good condition.

Status of the exhaust system affects also on the engine power and fuel consumption.


Fuel system can be removed as a complete and separate sections.
1. Lift the car and fix it on supports.
2. Remove the bottom mudguard of the engine.
3. Coat the nuts and the bolts securing the elements of the exhaust system means destroying rust. Wait a while until the rust will not be destroyed completely.

Gasoline engines

1. Disconnect the oxygen sensor electrical connector. On the six-cylinder engines disconnect connectors from the two oxygen sensors. The oxygen sensor connector located on the bulkhead.
2. Remove the mounting front of a reception exhaust pipe from the exhaust manifold. Support exhaust system jack or tie it with wire to the bottom of the car.

Engines 1,8-I ADR and six-cylinder engines

1. Remove the mounting reception exhaust pipe to the bracket located on the gearbox.
2. Remove the exhaust system of rubber suspension and remove it from under the car.


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 compound from the remnants of sealant and rust.

The engine 1,8-I ADR and six-cylinder engine

1. Unscrew the bracket supporting a reception exhaust pipe from the gearbox. See fig. Elements of the bracket to support the reception of the exhaust pipe.
2. Insert the exhaust system into the rubber cushions, but at this stage do not tighten the bolts.
3. Boltvmi catalyst screw with a new seal to the reception exhaust pipe, but at this stage do not tighten the screws completely.
4. If necessary, turn the section of the exhaust system so that the entire exhaust system was located at a distance of not less than 25 mm from the body.
5. Move the exhaust system so as to mount the exhaust system in rubber cushions was moved forward by 7-9 mm (see. Fig. Distance (a) by which to shift the exhaust system during installation). This is necessary to ensure that the heating and thermal expansion of the exhaust system it established in the correct position.
6. Finally, tighten all nuts and bolts securing the exhaust system (see. Table tightening moments).
7. Install the lower engine cover.
8. Connect the electrical connections of oxygen sensors.
9. Lower the car to the ground.
10. Start the engine and check the tightness of the exhaust system.

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