Instructables
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Replace the exhaust system on a VW rabbit.  

I could not find much info on the details of installing a muffler.  Hopefully this will help if you have to do the same thing

This was physically difficult for me to do, a lot of being under the car, which I don't like.

Note: The red bentley manual as a good exploded view, it also has the torque spec for the pipe clamps ... although I seem to have lost it.... you can get them from amazon here  
 
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Step 1: Get the parts

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This is a complete replacement exhaust with accessories and tools.

Step 2: Document part numbers

Picture of Document part numbers
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I photograph all the labeling as soon as I open the boxes.  If you need a part number latter, it is easier to look at the pictures then at the top of a muffler that is under a car.

Step 4: Spring clamps and tool

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Step 5: Rubber hangers

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Step 8: Inspect the pathway and hangers under the car

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Step 9: Remove the old down pipe

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Use the spring clip removal tool, to remove the spring clips.  I tightened it as much as possible and still could not remove the clips.  I oiled the area around the clips and was then able to remove them.

Will reuse the heat shields.

Not sure if there is a small crack in the exhaust manifold -- does not look like damage, but does not seem like it should be there.

Step 10: Jack up the back of the car and get a light

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Step 11: Install the tail pipe and muffler -- needs to be snaked into place

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Step 12: Secure with rubber hangers

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Step 13: Deal with rust

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Rust sucks.

Step 14: Chip and cut away all the rust

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Hitting the rust with a hammer will get rid of a lot of it.  Using a pointy hammer works well and helps you figure out where the edges of the rust are.

I used an angle grinder with a cut-off disc to cut back to good metal.

To weld you need a clean surface, so go around the edges with a wire  brush disc on the grinder.
marc.cryan (author) 1 year ago
late reply to VW diesel exhaust question ---- I have driven the car very little, so it is hard to say how good it really is. It has stayed on and exhaust comes out the end, and no where else. It does lean to one side, but it does not seem to matter.
How has it held up since then?