Exhaust Pipe With Catalytic Converter: Removing

WARNING: This page is about a different variant/trim than selected.

-- Release the tabs on the side and remove the cover -1- from the air duct.

Fig 1: Air Duct Cover & Air Duct

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Unclip the air duct -2-.

-- Remove the bolt -A-, disconnect the connector -B-, loosen the spring clamp -C- and remove the air filter housing and connecting pipe. Pay attention to the mark -D-.

Fig 2: Air Filter Housing Bolt, Connector, Spring Clip & Vacuum Line

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the throttle valve control module.

-- Disconnect all electric connectors for the heated oxygen sensors.

Fig 3: Identifying Electric Connectors

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Free up the electrical wires to the oxygen sensors.

-- Loosen the exhaust pipe to exhaust manifold nuts -arrows- (accessible from the top).

Fig 4: Front Exhaust Pipe To Exhaust Manifold Nuts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the noise insulation. Refer to DESCRIPTION AND OPERATION .

-- Remove the right drive axle heat shield bolts -arrows- and heat shield.

Fig 5: Drive Axle Heat Shield Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the exhaust pipe to exhaust manifold nuts -arrows- (accessible from underneath).

Fig 6: Front Exhaust Pipe To Exhaust Manifold Nuts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

Danger of causing damage to the coupling element.

Do not bend the coupling element more than 10°.
Do not stretch the coupling element.
Do not damage the wire mesh on the coupling element.

-- Free up the electrical wires to the oxygen sensors.

-- Remove the exhaust system suspended mount bracket bolt -arrows- from the subframe.

Fig 7: Identifying Suspended Mount Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the underbody tunnel braces -A and B-.

Fig 8: Identifying Tunnel Bridges

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Separate the exhaust system at the clamp -1-.

-- Remove the exhaust pipe with catalytic converters from the exhaust manifolds.