Audi Workshop Service and Repair Manuals

Removing and installing starter and main catalytic converter

Special tools and workshop equipment required

t	Hose clip pliers -V.A.G 1921-

t	Chain-type pipe cutter -VAS 6254-

t	Locating pins -T10096-

t	Setting tool -T40035-

Removing –  Remove bonnet → Chapter. –  Take off engine cover panel -arrows-. –  Remove noise insulation located below (detach crankcase breather hose).

–  Use screwdriver to lever of cover caps -3- and -4- from wiper arms. –  Slacken nuts on both wiper arms a few turns. –  Loosen wiper arms -1- and -2- from wiper shafts by tilting slightly. –  Completely remove nuts and take off wiper arms.

–  Disconnect washer fluid hose -3-. –  If fitted, unplug electrical connectors -4- and -5- for heated washer jets. –  Open hose clip -6- using hose clip pliers -V.A.G 1921- and detach water drain hose from cowl panel grille. –  Pull off rubber seal -1- on cowl panel grille. –  Disconnect cowl panel grille -2-.

–  Unscrew nuts and bolts -arrows-. –  Pull air duct forwards, move it to right side of vehicle and remove.

–  Unscrew nuts -arrows- at turbocharger/starter catalytic converter.

–  Remove noise insulation -arrows-.

–  Remove bolts -1- and -3- and detach pendulum support.   Note Disregard -item 2-.

–  Unbolt heat shield -arrow- for drive shaft (right-side).   Note

Do not bend the flexible joint (de-coupling element) between starter catalytic converter and main catalytic converter more than 10°, otherwise it could be damaged. –  Support flexible joint with fixing -T40035-.

–  Remove bolts -1- and -2- and detach bracket for starter catalytic converter. –  Disconnect starter catalytic converter from turbocharger. –  Remove heat shield panels below exhaust system from underbody.

–  On vehicles with two-piece exhaust pipes, loosen nuts on clamp -4- and move clamp towards rear to separate exhaust system. –  On vehicles with one-piece exhaust pipes, cut through exhaust pipe at a right angle at cutting point -2- using chain-type pipe cutter -VAS 6254-.

–  Locate subframe with locating pins -T10096--item 1- → Rep. Gr.40. –  Unscrew subframe from body -arrows- → Rep. Gr.40. –  Lower subframe approx. 40 mm.

–  Disengage rubber mountings for main catalytic converter -arrows-. –  Turn starter and main catalytic converter through 180° in anti-clockwise direction and remove (press engine/gearbox assembly to front). Installing Installation is carried out in the reverse order; note the following:   Note Renew gaskets and self-locking nuts. –  Install pendulum support → Chapter. –  Install subframe → Rep. Gr.40.

–  Install bracket for starter catalytic converter. Tightening sequence: 1.  Screw in bolt -1- finger-tight. 2.  Screw in bolt -2- finger-tight. 3.  Tighten bolt -1- to 23 Nm with torque wrench. 4.  Tighten bolt -2- to 23 Nm with torque wrench.

–  When reassembling, position the clamp -4- centrally over the markings -1- and -3-.

–  Install clamp so that bolts are positioned horizontally. l  Bolt connection faces downwards. Tightening torques

Component		Nm
Starter catalytic converter to turbocharger		23 1)2)
Bracket for starter catalytic converter to	Starter catalytic converter	23
	Cylinder block	23
Clamp		23
Drive shaft heat shield to gearbox		23
l  1) Renew nuts. l  2) Coat threads and contact surface of bolt heads with high-temperature paste; for high-temperature paste refer to → Parts catalogue.