Audi Workshop Service and Repair Manuals

Removing and installing front exhaust pipe (left-side) with starter catalytic converter and main catalytic converter - vehicles with manual gearbox or multitronic gearbox 01J

Removing –  Pull off engine cover panel (rear) -arrows-.

–  Remove cover -1- on left side of engine compartment.

–  Unbolt coolant expansion tank -arrow-. –  Unplug electrical connector for coolant shortage indicator switch -F66- at expansion tank (bottom) and move expansion tank to one side (coolant hoses -1 ... 3- remain attached).

–  If fitted, remove heat shield for connections from bulkhead (left-side). –  Remove electrical connectors -1 ... 4- from bracket (at left on bulkhead). –  Unplug electrical connectors -1- and -4-. –  Guide wiring for Lambda probes downwards.

–  Unscrew nut -2- (accessible from above) securing front exhaust pipe to exhaust manifold.   Note Shown in illustration with engine removed.

–  Remove front left wheel. –  Vehicles with auxiliary heater: remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Release bolts or quick-release fasteners -1- and -2- and take off front noise insulation. –  If fitted, open quick-release fasteners -3- and remove rear noise insulation.

–  Unbolt heat shield for drive shaft (left-side) -arrows-.   Note

To avoid any damage, the flexible joint in the front exhaust pipe must not be bent more than 10°. –  Disconnect exhaust system at clamp (left-side) -left arrow-.

–  Unbolt mounting plate for front exhaust pipe -arrow-.

–  Remove nuts -1- and -3- (accessible from below) securing front exhaust pipe to exhaust manifold.   Note Shown in illustration with engine removed. –  Move Lambda probe wires clear. –  Take out front exhaust pipe with starter and main catalytic converter. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets and self-locking nuts. t  Fit all cable ties in the original positions when installing. t  When installing, the Lambda probe wires must always be reattached at the same locations to prevent them from coming into contact with the exhaust pipe. –  Align exhaust system so it is free of stress: vehicles with front-wheel drive → Chapter, vehicles with four-wheel drive → Chapter.   Note Components of exhaust system mountings on gearbox: vehicles with manual gearbox and front-wheel drive → Fig., vehicles with manual gearbox and four-wheel drive → Fig., vehicles with multitronic gearbox 01J → Fig.. Tightening torques

Component		Nm
Front exhaust pipe with starter catalytic converter and main catalytic converter to:	Exhaust manifold	27
	Mounting plate	25
Shield for drive shaft to gearbox		23