Exhaust joining piece clamp rusted through

[RUM4MO]

This is a well know issue with all VW Group at least petrol, cars, usually around the 8 years 50,000miles mark one of the joining piece clamps ends up rusting all the way through and so needing replaced before the second one does the same.

For me, it was the spotting of lots of bits of rust had suddenly appeared on the garage floor when I put it back into the garage, that gave the game away right away I guessed what had happened - been there done that in the past. I had bought a NOS genuine VW Group part on ebay over 2 years ago, which was probably when VW Group last revised this part so stocks of discontinued parts would have been auctioned off.

The saving grace on these cars is that there is a body cross brace near this point in the exhaust run, so at least the rear section of exhaust should never end up dropping down too far when the second clamp fails and the joining sleeve expands and so becomes free to move along the exhaust.

What I'm suggesting is, if your car is in the age range of 8>9 years old and roughly 50,000miles, take a look underneath to see what condition the joining piece is in as it could spoil your plans if it's clamps rust through when you are out and about. I've been keeping an eye on this and if this had not failed before its next MOT in August, I was going to replace it to avoid getting an advisory.

[Le_Combattant]

Do you have the picture/part number for this piece ?

My car is 10 years old but not too much rust.

[2226]

Most likely these clamps:

silencers.JPG (23.35 KiB) Viewed 2400 times

Items 3 and 4.

Speaking of exhausts...
How many cats on the CJZD?

cats.JPG (22.82 KiB) Viewed 2400 times

There's the cat up top at the turbo, but what are these other 2 units? Resonators?

[Le_Combattant]

Most likely these clamps:

silencers.JPG

Items 3 and 4.

Speaking of exhausts...
How many cats on the CJZD?

cats.JPG

There's the cat up top at the turbo, but what are these other 2 units? Resonators?

To honest, now IDK. For me one, right after the turbo. I don't know what are those devices.

[2226]

I guess need to look at where the 2nd O2 sensor is. I've never really checked.
I think that's just the resonator; after that is the 2 mufflers.

My exhaust is showing surface corrosion. Guess I should check the clamps at some point, but it's pretty dry here.

[CarbonChaos]

The first ( nearest the motor)most likely a flexible joint the second is definitely a cat

[Le_Combattant]

The first ( nearest the motor)most likely a flexible joint the second is definitely a cat

EA211 hase their cat right after turbo. It's not a flexible joint.

[2226]

Petrol particulate filter.

[RUM4MO]

The first "red arrow" in the diagram above is the flexi section.

The part number of the joining piece I fitted was 1KO 253 141 M but I think that the design has now been changed to either make these joining pieces more robust or just cheaper (to manufacture).

You could just fit any suitably sized clamps over the split joining piece, but the split joining section (one inside the other), has a raised dimple at each end to locate the correct design of clamps which are part of this joining piece, if you used any other or better clamps, maybe stainless steel even, you would need to either deform both clamps at the same points as the originals, or drill a hole on each 90 degrees round from the clamping areas.

Edit:- ie stainless steel Mikalor W2 SS T Bolt Clip 55mm – 59mm width 28mm would fit.

[2226]

The other red arrow is the particulate filter. Only found reference to this is one of the maintenance documents.
The maintenance document for the 1.0tsi has a ton more stuff going on. Very weird.

I think exhaust sleeve clamps without the dimple will work as well. The clamps on the VW part seem to be mild steel. Was it the clamp that rust out or the connecting pipe material?

[RUM4MO]

I think exhaust sleeve clamps without the dimple will work as well. The clamps on the VW part seem to be mild steel. Was it the clamp that rust out or the connecting pipe material?

Oh yes, just the mild steel clamps!

The worst of the damage/wear and tear to the split connecting piece was rust staining on the surface of the stainless steel.

I'm sure that the design for these joining pieces have all been revised and now look like they just have "lugs with holes" at each end for a clamping bolt to pass through - so no longer 2 clamps plus split joining piece, just split joining piece plus 2 clamping bolts and nuts - or nuts crimped to the split joining piece.

Edit:- in case anyone goes looking for one of these joining pieces, it seems that the part number is still 1K0 253 141 M and its dimensions are 55mm X 95mm, which is useful to know if you go looking for an aftermarket version.