Audi Workshop Service and Repair Manuals

Removing and installing front exhaust pipe (left-side) with starter catalytic converter and main catalytic converter Special tools and workshop equipment required

t  Engine and gearbox jack -V.A.G 1383 A-

t  Spark plug connector pliers -V.A.G 1922- Removing   Note t  Fit all heat insulation sleeves in the original position when installing. t  All cable ties which are released or cut open when removing must be fitted in the same position when installing.

–  Remove cover -1- at right of engine compartment.   Note Disregard items marked -2- and -3-.

–  Unfasten screw connections -arrows- and detach engine cover panels -A ... C-.

–  Unscrew hose connections and bolt connections on the air duct at the points indicated by -arrows- and remove the air duct.

–  Detach vacuum line -arrow- going to brake servo at bulkhead.

–  Unbolt coolant expansion tank -2--arrows-. –  Unplug electrical wire for coolant shortage indicator switch -F66- at bottom of expansion tank and move expansion tank to one side with coolant hoses -1- and -3- attached.

–  Detach rubber seal from plenum chamber cover in direction of -arrow-. –  Detach plenum chamber cover -1- towards the front.

–  Remove cover for electronics box in plenum chamber -arrows-.

–  Carefully lever off retaining strap with a screwdriver -arrow-. –  Lay aside engine control unit with electrical connectors attached.

–  Release retainer -arrow- and pull auxiliary relay carrier in electronics box upwards to remove. –  Disconnect the electrical connectors at connector point using spark plug connector pliers -V.A.G 1922-.

–  Detach earth connection -2- and retainer -1- for electrical connectors from bulkhead. –  Disengage engine wiring harness at electronics box and bulkhead -arrows- and move clear.

–  Take electrical connector -2- for Lambda probe 2 -G108- out of bracket (left-side) at bulkhead and unplug. –  Remove heat insulation sleeve at wiring harness and move wire to Lambda probe clear.

–  Take electrical connector -2- for Lambda probe 2 after catalytic converter -G131- out of bracket (right-side) on bulkhead and unplug it. –  Remove heat insulation sleeve at wiring harness and move wire to Lambda probe clear.

–  Unscrew bolts -1- and -3- for heat shield. –  Unscrew top nut -2- securing front exhaust pipe to turbocharger.

–  Remove noise insulation -arrows-.

–  Unbolt heat shield -1- for drive shaft (left-side). –  Detach drive shaft (left-side) from flange shaft of gearbox.   Note

To avoid any damage, the flexible joint in the front exhaust pipe must not be bent more than 10°. –  Disconnect exhaust system at clamps -1-.   Note Disregard -item 2-.

–  Unscrew bolts -1- and -2- and remove mounting for front exhaust pipe (left-side).

–  Unbolt cross piece from subframe -arrows-.

–  Apply lifting column of engine/gearbox jack -V.A.G 1383 A- at centre of gearbox housing casting -arrow- and support gearbox from below.   Note

The lock carrier must be installed. –  First remove bolts -2- and -3- and then bolts -1- and -4-. –  Lower gearbox and subframe slowly using engine and gearbox jack -V.A.G 1383 A-.   Note Make sure that the propshaft joint is not damaged when lowering gearbox.

–  Remove heat shield for gearbox support (left-side) -arrows-. –  Remove bolts and take off gearbox support with gearbox mounting. –  Move Lambda probe wires clear.

–  Slacken hose clip -1- on heat shield for front exhaust pipe –  Unscrew nuts -2- securing front exhaust pipe to turbocharger. –  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  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. t  Fit all heat insulation sleeves in the original position when installing. t  Fit all cable ties in the original positions when installing. –  Install gearbox support with gearbox mounting → Rep. Gr.34. –  Install subframe → Rep. Gr.40.   Note Mounting components for exhaust system on gearbox → Fig.. –  Align exhaust system so it is free of stress → Chapter. Tightening torques

Component		Nm
Front exhaust pipe with starter catalytic converter and main catalytic converter to:	Turbocharger	30 1)
	Mounting bracket	25
Mounting bracket to gearbox support		25
Drive shaft heat shield to gearbox		23
Heat shield for front exhaust pipe		10
Air duct to intake manifold		10
l  1) Renew nuts.