4. Exhaust System

The exhaust system is bolted together at welded flanges or clamped together at slip-joints. Slots and dimples are incorporated into the mating flanges to ensure proper alignment. An individual gasket is used at each of the four exhaust manifold ports for mounting to the cylinder head. One gasket is also used at the front pipe to exhaust manifold joint, fastened with either spring clamps or a bolted flange, depending on the engine, as shown in Fig. 4-1, Fig. 4-2, Fig. 4-3, and Fig. 4-4. The metal heat shield is attached to the front pipe at the mounting flange.

Fig. 4-1.

Manifold and front pipe assembly used on GTI Golf and Jetta with GX, HT, and RV engines, and GTI with RD engine.

Fig. 4-2.

Manifold and front pipe assembly used on Golf and Jetta with PF engine, Jetta GLI with RD engine, and all 16-valve (PL) engines.

Fig. 4-3.

Exhaust manifold and front pipe assembly used on Jetta models with 2.0 liter 16-valve (9A) engine Exhaust Gas Recirculation (EGR) Valve and components used only on California models.

Fig. 4-4.

Exhaust manifold and front pipe assembly used on Canada models with MZ engine, and all diesel, turbo diesel, and ECO diesel engines (ME, MF, and 1V).

From the catalytic converter back, the mufflers and pipes are joined together with slip-joints secured with circular clamps, as shown in Fig. 4-5, Fig. 4-6, and Fig. 4-7. Brackets welded to the pipes and mufflers support the system by rubber retaining rings connected to brackets on the body.

Fig. 4-5.

Rear section of exhaust system used on all gasoline engines (GX, MZ, HT, RD, RV, and PF) except 16-valve.

Fig. 4-6.

Rear section of exhaust system used with all 16-valve (PL and 9A) engines.

Fig. 4-7.

Rear section of exhaust system used with diesel, turbo diesel, and ECO diesel (ME, MF and 1V) engines.