Volkswagen Golf/Jetta/Cabriole 1990-1999

Exhaust Manifold

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REMOVAL & INSTALLATION





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Fig. Exploded view of the exhaust manifold mounting and related components-1.8L engine



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Fig. Exploded view of the exhaust manifold mounting and related components-2.0L (ABA) engine



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Fig. Remove the emissions testing tube



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Fig. Heat shield bolt location



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Fig. Remove the exhaust manifold heat riser by sliding it towards the firewall and then pulling it up and out



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Fig. Once the exhaust manifold bolts have been removed, pull the manifold toward the fire wall and then out



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Fig. It is advised that you replace the exhaust manifold gasket every time the manifold is removed. This will ensure a tight seal to the head



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Fig. View of exhaust manifold to down pipe gasket



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Fig. Exhaust manifold bolts are subject to extreme amounts of heat. This may lead them to break off upon removal. You may have to drill out the broken stud



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Fig. Always use two hands when using and easy out or screw extractor



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Fig. Slowly turn the screw extractor into the screw. The use of a penetrating oil is recommended



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Fig. Exhaust pipe-to-manifold torque sequence-2.0L (ABA) engine



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Fig. Exploded view of the exhaust manifold mounting and related components-2.8L (AAA) engine



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Fig. Exploded view of the exhaust manifold mounting and related components-2.8L (AHA) engine

  1. Disconnect the Oxygen (O 2 ) sensor wiring and remove any heatshields that may be in the way.
  2.  
  3. Remove exhaust support brackets as necessary.
  4.  
  5. Detach the front exhaust pipe from the manifold or turbocharger.
  6.  
  7. If equipped, remove the turbocharger.
  8.  
  9. Remove the self-locking nuts or bolts and remove the manifold.
  10.  

To install:

  1. Installation is the reverse of removal. Use new gaskets and self-locking nuts and tighten to 18 ft. lbs. (25 Nm).
  2.  
  3. If the exhaust pipe is bolted to the manifold, install a new gasket and use new self-locking nuts. Tighten the nuts to 30 ft. lbs. (40 Nm).
  4.  
  5. Check and clear any Diagnostic Trouble Codes (DTCs).
  6.  

 
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