Audi Workshop Service and Repair Manuals

Removing and installing front exhaust pipe (left-side) with starter catalytic converter and main catalytic converter Special tools and workshop equipment required

t  Hose clamps for hoses up to 25 mm Ø -3094-

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

–  Remove cover -1- on left side of engine compartment.

–  Clamp off coolant hose -2- using hose clamp -3094- and detach coolant hose from coolant expansion tank. –  Unbolt coolant expansion tank -arrow-. –  Disconnect electrical wiring for coolant shortage indicator switch -F66- at coolant expansion tank (bottom). –  Tie coolant expansion tank to one side; coolant hoses -1- and -3- remain connected.

Vehicles with automatic gearbox 01J: –  Disconnect vacuum line leading to brake servo -arrows-.

All models: –  If fitted, remove heat shield for connections from bulkhead (left-side). –  Detach connectors -1 ... 5- from retainer at left of bulkhead. –  Unplug electrical connectors -2- and -5-. –  Guide wiring for Lambda probes downwards.

–  Unscrew nut -2- (accessible from above) connecting front exhaust pipe to exhaust manifold.   Note Illustration shows engine removed. –  Remove front left wheel.

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

–  Release bolts or quick-release fasteners -1- and -2- and take off front noise insulation. –  If fitted, open quick-release fasteners -3- and remove rear noise insulation.

–  Remove front cross-piece for underbody -1 … 4-.   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-side) -left arrow-.

–  Unbolt heat shield -1- for drive shaft (right-side).

–  Unbolt bracket for front exhaust pipe -arrow-.

–  Unscrew nuts -1- and -3- (accessible from below) connecting front exhaust pipe to exhaust manifold.   Note Illustration shows engine removed. –  Remove front exhaust pipe with catalytic converter. Installing Installation is carried out in the reverse order; note the following:   Note t  All cable ties which are released or cut open when removing must be refitted in the same position when installing. t  When installing, the Lambda probe wires must always be reattached at the same locations to prevent them from coming into contact with the exhaust pipe. t  Renew gaskets and self-locking nuts. –  Align exhaust system so it is free of stress → Chapter.   Note Components of exhaust pipe mountings on gearbox → Fig. (vehicles with manual gearbox) or → Fig. (vehicles with automatic gearbox 01J). Tightening torques

Component	Nm
Front exhaust pipe with catalytic converter to exhaust manifold	27
Mounting bracket to front exhaust pipe with catalytic converter	25
Mounting plate to gearbox	25
Shield for drive shaft to gearbox	23