Audi Workshop Service and Repair Manuals > A3 Mk2 > Power unit | 4-cylinder injection engine (1.6 ltr. 2-valve), mechanics | Exhaust system | Silencers and exhaust manifold - vehicles with engine codes BGU, BSE, BSF, CCSA

Removing and installing exhaust manifold

Removing

–	Remove front exhaust pipe together with catalytic converter → Chapter.

–	Remove intake manifold → Rep. gr.24.

–	Remove electrical connector -arrow- for Lambda probe -G39- (before catalytic converter) from bracket and unplug connector.

Vehicles with engine code BGU:

–	Unscrew clamp -2-.

–	Loosen union nut -1-.

–	Remove nuts -3- and remove connecting pipe for exhaust gas recirculation.

All vehicles (continued):

–	Remove nuts -1- for heat shield -3-, and detach washers -2-.

–	Remove nuts -8- on both brackets -4-, and detach washers -7-.

–	Unscrew the remaining nuts on exhaust manifold -6- and remove washers.

–	Detach exhaust manifold and gasket -5-.

Installing

Installation is carried out in the reverse order; note the following:

Note

Renew gaskets and self-locking nuts.

–	Install intake manifold → Rep. gr.24.

–	Install front exhaust pipe together with catalytic converter → Chapter.

–	Align exhaust system so it is free of stress → Chapter.

Component

Exhaust manifold to cylinder head

25 ¹⁾²⁾

Heat shield to exhaust manifold

EGR connecting pipe to EGR valve

EGR connecting pipe to exhaust manifold

l	¹⁾ Lubricate exhaust manifold studs with high-temperature paste. For high-temperature paste refer to → Electronic parts catalogue.

l	²⁾ Renew self-locking nuts.

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