Audi Workshop Service and Repair Manuals

Removing and installing exhaust manifold

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

–  Release quick-release fasteners -1- and -2- and take off front noise insulation.

–  Unscrew bolts -1- and -2- several turns.

–  Release quick fasteners -arrows- and remove engine cover panel.

–  If fitted, detach cover -1- on right of engine compartment.

–  Disengage solenoid valve 1 for activated charcoal filter system -N80- at air duct. –  Remove bolts -arrows-. –  Remove air duct -2-.

–  Unplug electrical connector -3- at solenoid valve 1 for activated charcoal filter system -N80- and the electrical connector -5- at air mass meter -G70-. –  Detach hoses -1-, -4-, -6- and -7-. –  Remove fastener -2- and detach air cleaner housing.

–  Disconnect front hose from pipe -2- for crankcase breather. –  Disconnect front hose from pipe leading to combination valve for secondary air -1-. –  Remove heat shield -3-.

–  Remove bolts -1- and -2- on oil supply pipe. –  Unscrew bolts -3- for turbocharger. –  Remove gasket between turbocharger and exhaust manifold. –  Seal opening in turbocharger with a clean cloth.

–  Unscrew all nuts -arrows- on exhaust manifold. –  Remove washers and exhaust manifold. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets and self-locking nuts. t  Check that sealing surface is clean. –  Keep to the sequence as listed below: 1 -  Exhaust manifold to cylinder head 2 -  Turbocharger to exhaust manifold 3 -  Bracket for turbocharger to cylinder block 4 -  Bracket for turbocharger to turbocharger Tightening torques Tightening torques

Component		Nm
Exhaust manifold to cylinder head		25
Turbocharger to exhaust manifold		35 → Remark → Remark
Bracket for turbocharger to:	Cylinder block	25
	Turbocharger	30
Oil supply pipe to cylinder head		20
Crankcase breather pipe to cylinder head		10
Hose clips (9 mm wide)		3
Hose clips (13 mm wide)		5.5

1)  Renew bolts. 2)  Coat thread and contact surface of bolt head with high-temperature paste; → Parts catalogue