Monday, November 25, 2013
Jetta Exhaust Removal
The method of removing the exhaust manifold in a Volkswagen Jetta varies greatly, especially based on the type of engine the car has. No matter what the case, it is a complex procedure that should only be attempted by someone with extensive knowledge of the exhaust system. Consult with your mechanic before taking on this task.
1.8 Liter Engine
To remove the Jettas engine cover, pry off the plastic caps covering the screws, remove all the retaining nuts and detach the cover. Next, remove the air intake duct by squeezing the tabs on its hose clamp. Take off the cowl cover by disconnecting the windshield wiper arms, pulling off the weatherstrip at the covers front end, removing the pollen filter cover and releasing the clips on the covers sides.
On a 1.8 liter engine, you will need to remove the turbocharger and all of its related components. Drain the engine coolant into a container by removing the plug at the radiator and then at the engine oil cooler. Raise and support the Jetta on jack stands and then remove the engine compartment undercover. Remove the nuts attaching the exhaust pipe to the turbocharger. Next, lower the exhaust pipe by removing its support bolts. Disconnect all hoses and parts connected to the turbocharger; this includes the support bracket, the vacuum hose from the wastegate actuator, outlet pipe and elbow, the coolant return pipe and the oil supply pipe. Locate and remove the heat shield, then take off the bolts connecting the turbocharger to the manifold lower and tilt the turbocharger so you can disconnect the coolant supply pipe, allowing you to completely disconnect the turbocharger.
Once you have the turbocharger off, you can remove all of the nuts and bolts for the manifold and detach it with its gasket.
2.0 Liter Engine
For 2.0 liter engines, you may need to remove the oil dipstick when you detach the engine cover. After taking off the air intake duct (disconnect the accelerator cable with the duct) and cowl cover as described above, remove the upper intake manifold--clamp off the coolant hoses connected to the throttle body with hose clamps, disconnect the hoses and electrical connectors along with the ones connected to the upper manifold, and remove the bolts at the rear of the manifold for the warm air deflector plate. Disconnect the vacuum hose leading to the brake booster, and loosen each manifold bolt a quarter turn at a time with the wrench until they are all loose. You can then remove them and the manifold with the throttle body attached.
Next, take off the hoses on the secondary air injection control valve. Raise the cars front end and support it on jack stands, then unbolt the inner CV joint on the right side, pushing the axle out of the way and securing it with a wire. Disconnect the electrical connectors to the oxygen sensor and the one to the front O2 sensor; detach the latter from the manifolds retaining bracket.
Finally, separate the air injection pipe by disconnecting its union nuts from the fittings on the manifold and the secondary air injection control valve. Remove the warm air deflector plate, then remove the exhaust manifolds nuts and bolts and detach it with the gasket.
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