Audi Workshop Service and Repair Manuals

Removing and installing exhaust manifold (left-side) Special tools and workshop equipment required

t  Lambda probe open ring spanner set -3337-

Removing   Note All cable ties which are released or cut open when removing must be refitted in the same position when installing. –  Pull off engine cover panel (rear) -arrows-.

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

–  Unscrew nut -2- (accessible from above) securing front exhaust pipe to exhaust manifold on the relevant side.   Note Shown from rear with engine removed for illustration purposes. –  Drain off coolant → Chapter. –  Remove front left wheel.

–  Unbolt heat shield -arrows- for drive shaft (left-side).

–  Unscrew nuts -1- and -3- (accessible from below) connecting front exhaust pipe to exhaust manifold.   Note Shown in illustration with engine removed.   Note

To avoid any damage, the flexible joint in the front exhaust pipe must not be bent more than 10°. –  Disconnect exhaust system at clamp -left arrow-. –  Push clamp back and pull front exhaust pipe off exhaust manifold.   Note The front exhaust pipe remains on the vehicle.

–  Unscrew securing bolts -3- and -4- for heat shield (accessible from below).

–  Pull off engine cover panel (front) -arrows-.

–  Detach coolant hose -arrow- from coolant pipe (front).

–  Remove coolant hose (front left) in engine compartment -arrows-.

–  Detach coolant hose -arrow- from coolant pipe (front).   Note

Lay a cloth under the hydraulic pipe to catch any escaping hydraulic fluid. –  Disconnect hydraulic pressure pipe -arrow- at power steering pump, lift clear and place pipe on longitudinal member.

–  Unplug electrical connector -arrow- at Hall sender 4 -G301-. –  Move wiring clear.

–  Unscrew securing bolts -1- and -2- for heat shield (accessible from above). –  Remove the heat shield.

–  Unplug electrical connector -2- for Lambda probe 2 -G108- and move wiring clear.   Note Disregard -item 1-.

–  Unscrew Lambda probe -1- using Lambda probe open ring spanner set -3337-.   Note t  Shown in illustration with engine removed. t  Disregard -item 2-.

–  Remove nuts -1- and -8- and detach bracket for heat shield. –  Unscrew nuts -2 ... 7- and -9- and remove exhaust manifold. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets, seals and self-locking nuts. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  Reinstall all cable ties in the same locations when assembling.

–  Secure exhaust manifold together with bracket for heat shield by tightening nuts in 2 stages in the sequence shown, as follows: 1 -  Initially tighten to 15 Nm. 2 -  Tighten to 25 Nm. –  Install Lambda probe → Rep. Gr.24. –  Install front exhaust pipe (left-side) with catalytic converter: vehicles with manual gearbox → Chapter; vehicles with automatic gearbox → Chapter. –  Align exhaust system so it is free of stress → Chapter.

–  Remove old O-ring -2- from coolant hose -3-. –  Lubricate new O-ring with coolant additive and fit O-ring in coolant hose. –  Press coolant hose onto coolant pipe -1- until it engages with a click. –  Press coolant hose in again and then pull to check that plug-in connector is correctly engaged. –  Fill cooling system → Anchor. –  Check fluid level of power steering and top up if necessary → Rep. Gr.48. Tightening torques

Component	Nm
Exhaust manifold to cylinder head	25 1)2)
Heat shield to bracket for heat shield	10
Hydraulic pressure line to power steering pump	47
Drive shaft heat shield to gearbox	23
l  1) Renew nuts. l  2) Grease with high-temperature paste; refer to → Electronic parts catalogue for high-temperature paste