Audi Workshop Service and Repair Manuals

Removing and installing catalytic converter with front exhaust pipe Special tools and workshop equipment required

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

Removing –  Unplug electrical connector -arrow- for Lambda probe -G39- and move wiring clear.

–  Remove both front wheels. –  Unbolt bracket for headlight range control sender in wheel housing (left-side, top) -arrows-. –  Detach linkage for headlight range control from wishbone and unplug electrical connector.

–  Remove centre noise insulation -arrows-.

–  Remove left noise insulation -arrows-.

–  Remove right noise insulation -arrows-.

–  First remove bolts -A-, then bolts -B- and remove pendulum support.

–  Disengage rubber mounting at front exhaust pipe -arrow-. –  Unscrew bolts -2- for steering box and pry off steering box from subframe (dowel sleeve). –  Unbolt bracket for power steering pressure pipe on left of subframe. –  Set up engine and gearbox jack -V.A.G 1383 A- below subframe. –  Remove subframe bolts -1- and -3-. –  Carefully lower subframe and leave it attached at the swivel joints and coupling rods; at the same time press steering box upwards.

–  Unbolt both brackets -arrows- for power steering pressure pipe from steering box.

–  Unscrew heat shield for drive shaft (right-side) from bevel box -arrows-.

–  Unbolt protective cover -2--arrows-. –  Unplug electrical connector for Lambda probe after catalytic converter -G130--item 1- and move wiring clear.

–  Unbolt catalytic converter from front exhaust pipe -arrows-.

–  Separate exhaust system at clamp -arrows-. –  Push the clamp back and remove the catalytic converter.

–  Unbolt front exhaust pipe from connection at turbocharger.   Note t  The top bolts securing the front exhaust pipe are accessible through the brake pipe opening in the right wheel housing (remove plug). t  To avoid any damage, the flexible joint in the front exhaust pipe must not be bent more than 10°. –  Remove front exhaust pipe.

Installing   Note Renew gaskets and self-locking nuts. –  Secure front exhaust pipe to turbocharger. –  Secure catalytic converter to front exhaust pipe -arrows-.

–  Fit clamp and tighten bolt connections -arrows- only hand-tight.

Install subframe as follows: –  Move subframe to installation position and tighten bolts hand-tight. –  Use new securing bolts. –  Bring steering box into position on subframe and insert steering box bolts. l  Threaded sleeve -1- must be located in hole in subframe. l  Rubber pad on opposite side should be located on projection on subframe. –  Secure steering box → Rep. Gr.48. –  Secure subframe → Rep. Gr.40.

–  Secure pendulum support -arrows-. –  Use new securing bolts. –  Align exhaust system so it is free of stress → Chapter. –  Perform road test to check position of steering wheel after installing.   Caution Check and adjust wheel alignment if the steering wheel is not centralised correctly. Tightening torques

Component		Nm
Front exhaust pipe to turbocharger		40
Catalytic converter to front exhaust pipe		23
Pendulum support to:	Gearbox	40 + 90° 1)2)
	Subframe	20 + 90° 1)2)
Drive shaft heat shield to bevel box		25
l  1) Renew bolts. l  2) 90° = one quarter turn.