Safety Warning

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HOMESERVICE MANUALSVOLKSWAGEN2002JETTA GLS, 4D SEDAN, 1.8 D, AUTOMATICREPAIR AND DIAGNOSISENGINE MECHANICALEXHAUST1.8L - EXHAUST SYSTEM, EMISSION CONTROLS - AWD, AWP, AWW GENERIC (A4 PLATFORM)EXHAUST SYSTEM, EMISSION CONTROLSEXHAUST SYSTEM COMPONENTS, REMOVING AND INSTALLINGNOTES

2002 Volkswagen Jetta GLS, 4D Sedan, 1.8 D, Automatic

Exhaust System Components, Removing And Installing: Notes

2002 Volkswagen Jetta GLS, 4D Sedan, 1.8 D, AutomaticSECTION Notes

NOTE:

After exhaust system repairs, make sure exhaust system is not under stress and that it has sufficient clearance from the bodywork. If necessary, loosen double clamps and clamp and align exhaust pipe so that sufficient clearance is maintained to the bodywork and support rings carry uniform loads.
Do not use any silicone sealant. Traces of silicone components which are sucked into the engine are not burned there, and they damage the oxygen sensor.
Always replace self-locking nuts.
Components marked with * are checked via On Board Diagnostic (OBD).

Check catalytic converter, see THREE WAY CATALYTIC CONVERTER (TWC), CHECKING .

The following list pertains to Fig 1.

Tunnel bridge
Suspended mount
- Note installed position, see Installation position of muffler suspension
25 Nm
Front exhaust pipe with catalytic converter
- Check catalytic converter, see THREE WAY CATALYTIC CONVERTER (TWC), CHECKING
40 Nm
- replace
Seal
- replace
Turbocharger
Heated Oxygen Sensor (HO2S) -G39- bank 1*, 50 Nm
- Only use "G 052 112 A3" to grease thread; do not let "G 052 112 A3" get onto slit of oxygen sensor
- remove and install using ring spanner 7-piece set (3337) for oxygen sensor
- If seal is leaking, cut open seal and replace seal
- Check oxygen sensor heater for Oxygen Sensor (O2S) before Three Way Catalytic Converter (TWC), see OXYGEN SENSOR HEATER FOR OXYGEN SENSOR BEFORE THREE WAY CATALYTIC CONVERTER (TWC), CHECKING
- Check Oxygen Sensor (O2S) and oxygen sensor control before Three Way Catalytic Converter (TWC), see OXYGEN SENSOR (O2S) AND OXYGEN SENSOR CONTROL BEFORE THREE WAY CATALYTIC CONVERTER (TWC), CHECKING
Connector
- For Heated Oxygen Sensor (HO2S) - G39- and Oxygen Sensor (O2S) Heater -Z19-
  Vehicles with engine code AWD:
- Black, 4-pin
  Vehicles with engine code AWP, AWW:
- Black, 6-pin
- Terminals are gold-plated
Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) - G130- bank 1*, 50 Nm
- Only use "G 052 112 A3" to grease thread; do not let "G 052 112 A3" get onto slit of oxygen sensor
- remove and install using ring spanner 7-piece set (3337) for oxygen sensor
- If seal is leaking, cut open seal and replace seal
- Check oxygen sensor heater for Oxygen Sensor (O2S) behind Three Way Catalytic Converter (TWC), see OXYGEN SENSOR HEATER FOR OXYGEN SENSORS BEHIND THREE WAY CATALYTIC CONVERTER (TWC), CHECKING
- Check Oxygen Sensor (O2S) and oxygen sensor control behind Three Way Catalytic Converter (TWC), see OXYGEN SENSOR AND OXYGEN SENSOR CONTROL BEHIND THREE WAY CATALYTIC CONVERTER (TWC), CHECKING
Connector
- For Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- and Oxygen Sensor (O2S) Heater 1 -Z29-
- Black, 4-pin
- Terminals 3 and 4 gold-plated
Double clamp
- Note installed position, see Installation position of double clamp
40 Nm
Suspended mount
Center and rear muffler
- At factory, center and rear mufflers are installed as a single component. Replacement center and rear mufflers are supplied separately, with double clamp for connecting joint.
- Separating point: see Separation point at exhaust pipe
- Install muffler free of tension, see Installing muffler free of tension
Suspended mount

Fig 1: Exploded View Of Exhaust System Components With Torque Specifications

Courtesy of VOLKSWAGEN OF AMERICA, INC.

RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.