Fig. 5.75. System of production of the fulfilled gases on cars with PF and RV engines: 1 – thermofilter; 2 – nut; 3 – reception exhaust pipe; 4 – sealing ring; 5 – final collector; 6 – nut; 7 – connecting coupling; 8 – a pipe of measurement of contents WITH; 9 – cap; 10 – reception exhaust pipe (RV); 11 – nut; 12 – lambda sensor; 13 – sealing ring; 14 – catalytic converter (RF); 15 – forward muffler; 16 – blooming plug; 17 – suspension bracket; 18 – bolt; 19 – b distance = 9–11 mm; 20 – back muffler; 21 – the place of drawing marking (S — the mechanical transmission, And — the automatic transmission); 22 – distance and = 5 mm; 23 – average muffler

Fig. 5.77. System of production of the fulfilled gases on cars with KR and 9A engines: 1 – laying; 2, 4, 14 – nuts; 3 – final collector; 5 – reception exhaust pipe and muffler; 6 – blooming plug; 7 – forward muffler; 8 – the place of drawing marking (S – the mechanical transmission, And – the automatic transmission); 9 – and = 5 mm; 10 – suspension bracket; 11 – back muffler; 12 – average muffler; 13 – thermofilter

Fig. 5.78. System of production of the fulfilled gases on cars with engines 9A with the catalyst: 1 – consolidation; 2 – nut; 3 – final collector; 4 – connecting plug; 5 – a tube of measurement of contents WITH; 6 – cap; 7, 20 – nuts; 8 – reception exhaust pipe; 9 – lambda sensor; 10 – sealing ring; 11 – catalytic converter; 12 – blooming plug; 13 – forward muffler; 14 – the place of drawing marking (S – the mechanical transmission, And – an automatic box before); 15 – and = 5 mm; 16 – suspension bracket; 17 – back muffler; 18 – average muffler; 19 – thermofilter

The system of production of the fulfilled gases (fig. 5.75, 5.76, 5.77, 5.78) needs to be checked for existence of damage, progar, leaks, integrity and reliability of fasteners, etc. regularly.

Before removal or dismantling of system of release it is necessary to moisten all all places of connections of pipes and fasteners with the liquid dissolving karrooziya products, for example WD-40.

Before any work with system of release wait for it so far elements will cool down.

It is possible to check system for leaks as follows:

– start the engine;

– after the assistant for a short time closes a rag an exhaust pipe, examine attentively from all directions system;

– if from connections, welded seams or elements of system there are fulfilled gases — neokhody repair of the damaged site.

On cars with the RP engine it is necessary to disconnect the exhaust system on connection of a collector with a reception exhaust pipe. Except for cars with the RP engine, it is simpler to remove the exhaust system from the car entirely and then to divide into parts or to cut off a defective part a hacksaw. On cars with the Lambda sensor, at removal of the exhaust system, disconnect the electric socket from the sensor.

Begin installation of the exhaust system with a forward part.

Carry out removal and installation of a final collector in the following order:

– remove an inlet collector;

– turn off fastening and disconnect a zabornik of the warmed-up air from a final collector;

– remove thermofilters;

– lift a forward part of the car and reliably record it on supports;

– under the bottom of the car disconnect a reception exhaust pipe from a collector flange;

– on all cars except for cars with the RP engine: the flange is attached by nuts 11 (see fig. 5.75 ) and hairpins;

– turn off nuts and disconnect a reception exhaust pipe 3 from a final collector 3;

– remove laying 2;

Fig. 5.76. System of production of the fulfilled gases on cars with RP engines: 1 – laying; 2 – final collector; 3 – nuts; 4 – connecting plug; 5 – a tube of measurement of contents WITH; 6 – cap; 7 – lambda sensor; 8 – fastening bracket; 9 – blooming plug; 10 – the place of drawing marking (S – the mechanical transmission, And – the automatic transmission); 11 – bolt; 12 – distance and = 5 mm; 13 – reception exhaust pipe; 14 – sealing ring; 15 – catalytic converter; 16 – nut; 17 – intermediate pipe; 18 – suspension bracket; 19 – average muffler; 20 – back muffler; 21 – suspension bracket arm; 22 – b = 9 – 11 mm; 23 – place of drawing marking; 24 – thermofilter; 25 – sealing ring

– on cars with the RP engine: connection of a final collector 2 (see fig. 5.76 ) with a reception exhaust pipe 13 is carried out by two rigid brackets 8;

– for a release of each bracket it is necessary to use the special VW 4140A/2 tool which represents a wedge-shaped plate (it can be made easily independently). After installation of a wedge-shaped plate move an exhaust pipe to the jammed bracket to a bracket to reduce a gap in connection and take a bracket. Keep in mind that brackets fasten in a certain situation basic surfaces on flanges;

– lower a reception exhaust pipe 13 and remove a sealing ring 25;

– unscrew nuts and bolts of fastening of a final collector 2;

– disconnect a collector and laying 1 from a head of the block of cylinders.

You carry out installation to the sequences of the return to removal. Use new laying and new самоконтрящиеся nuts. If necessary replace a sealing ring 14 on the RP engine.