VW Passat B5

since 1996 release

Repair and operation of the car



Foltsvagen Passat B5
+ Maintenance instruction
+ 1. Maintenance
+ 2. Engines
+ 3. Cooling system
+ 4. Fuel system
+ 5. Engine management
- 6. Exhaust system
   6.2. Catalyst
   6.3. Operation of cars with the catalyst
   6.4. Turbocharger
   6.5. Replacement of the muffler
   6.6. Oxygen sensor
+ 7. Transmission
+ 8. Running gear
+ 9. Steering
+ 10. Brake system
+ 11. Body
+ 12. Heating, ventilation
+ 13. Electric equipment






6. Exhaust system

6.1. General information

GENERAL INFORMATION

The exhaust system of front-wheel cars from four - and five-cylinder petrol engines


Prevention

In the drawing the exhaust system of the car with the engine 1,8-I ADR is presented.


1 – nut, 25 Nanometers,
2 – final collector,
3 – sensor of oxygen, 50 Nanometers,
4 – laying,
5 – reception exhaust pipe,
6 – nut, 30 Nanometers,
7 – nut, 25 Nanometers,
8 – catalyst,
9 – collar,
10 – pillow,
11 – bolt, 25 Nanometers,
12 – additional muffler,
13 – size A = 7–9 mm,
14 – junction of an exhaust pipe,
15 – central muffler,
16 – tightening bracket, 40 Nanometers,
17 – junction of an exhaust pipe,
18 – central muffler,
19 – suspension bracket,
20 – reception exhaust pipe,
21 – catalyst,
22 – washer


The exhaust system of front-wheel cars with the diesel engine

1 – additional muffler,
2 – central muffler,
3 – suspension bracket,
4 – bolt, 25 Nanometers,
5 – suspension bracket,
6 – tightening bracket, 40 Nanometers,
7 – intermediate pipe,
8 – nut, 25 Nanometers,
9 – turbocharger,
10 – laying,
11 – catalyst,
12 – bolt, 25 Nanometers,
13 – laying,
14 – nut, 25 Nanometers

Final collectors and reception exhaust pipes of cars with engines 6V (other part of the exhaust system same, as well as at all-wheel drive cars)

1 – plug,
2 – bolt,
3 – washer,
4 – arm,
5 – plug,
6 – rubber plug,
7 – nut, 25 Nanometers,
8 – spring,
9 – bolt, 25 Nanometers,
10 – to the central part of the exhaust system,
11 – the left reception exhaust pipe with the catalyst,
12 – sensor of oxygen No. 2, 50 of Nanometer,
13 – black four-contact electric socket,
14 – nut, 25 Nanometers,
15 – cap, 10 Nanometers,
16 – branch pipe,
17 – top thermofilter,
18 – lower thermofilter,
19 – left final collector,
20 – laying,
21 – right final collector,
22 – sensor of oxygen No. 1, 50 of Nanometer,
23 – the right reception pipe with the catalyst

The central and back part of the exhaust system on all-wheel drive cars from four - and five-cylinder engines

1 – bolt, 25 Nanometers,
2 – suspension bracket,
3 – nut, 40 Nanometers,
4 – the screw with a semicircular head,
5 – tightening bracket, 40 Nanometers,
6 – junction of pipes of the exhaust system,
7 – right additional muffler,
8 – suspension bracket,
9 – arm,
10 – left additional muffler,
11 – intermediate exhaust pipe,
12 – laying,
13 – catalyst,
14 – turbocharger,
15 – tightening bracket, 40 Nanometers,
16 – central muffler

Arm elements for support of a reception exhaust pipe

1 – buffer,
2 – plug,
3 – washer,
4 – left slip,
5 – washer,
6 – bolt,
7 – plug,
8 – right slip,
9 – spring,
10 – bolt,
11 – самоконтрящаяся nut, 25 Nanometers

Distance (a) on which it is necessary to displace the exhaust system at installation

and = 7 – 9 mm.

The arrow specifies the direction of the movement of the car.

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

On cars with V6 engines two separate exhaust systems are installed.

On cars with the all-wheel drive the double back muffler is installed.

Connection of elements of the exhaust system is carried out by threaded connections or tightening collars.

Problem of the exhaust system is removal of the fulfilled gases in the atmosphere so that they even in the minimum quantity did not get to interior of the car, and also reduction of noise of the engine to low level. That the exhaust system could perform the functions, it has to be in good repair.

The condition of the exhaust system exerts impact as well on the engine capacity and fuel consumption.

Removal

The fuel system can be removed as assembled, and on separate sections.
PERFORMANCE ORDER
1. Lift the car and fix it on supports.
2. Remove the lower mudguard of the engine.
3. Apply the means destroying a rust on nuts and bolts, the fixing elements of the exhaust system. Wait some time until the rust is destroyed completely.

Petrol engines

PERFORMANCE ORDER
1. Disconnect the electric socket of the sensor of oxygen. On six-cylinder engines disconnect sockets from two sensors of oxygen. Sockets of sensors of oxygen are located on a partition of a motor compartment.
2. Unscrew fastening of a forward part of a reception exhaust pipe from a final collector. Support the exhaust system a jack or tie it a wire to the car bottom.

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

PERFORMANCE ORDER
1. Unscrew fastening of a reception exhaust pipe to the arm located on the transmission.
2. Release the exhaust system from rubber suspension brackets and take it from under the car.

Installation

PERFORMANCE ORDER
1. For simplification of unscrewing in the subsequent the nuts and bolts fixing the exhaust system grease them with high-temperature Liqui Moly LM-508-ASC paste.
2. Before repeated connection of elements of the exhaust system clear their connection by an emery paper of the remains of sealant and a rust.

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

PERFORMANCE ORDER
1. Unscrew an arm of support of a reception exhaust pipe from the transmission, see rice. Arm elements for support of a reception exhaust pipe.
2. Establish elements of the exhaust system in rubber pillows, but at this stage do not tighten bolts.
3. Boltvmi screw the catalyst with new laying on a reception exhaust pipe, but at this stage do not tighten finally bolts.
4. If necessary turn sections of the exhaust system so that all exhaust system settled down at distance not less than 25 mm from a body.
5. Move the exhaust system so that fastening of the exhaust system in rubber pillows was shifted forward on 7–9 mm (see rice. Distance (a) on which it is necessary to displace the exhaust system at installation). It is necessary in order that when heating and thermal expansion of the exhaust system it was established in the correct situation.
6. Finally tighten all nuts and bolts fixing the exhaust system (see the table the tightening Moments).
7. Establish the lower casing of the engine.
8. Connect electric sockets of sensors of oxygen.
9. Lower the car on the earth.
10. Start the engine and check tightness of the exhaust system.