Audi Workshop Service and Repair Manuals

Removing and installing exhaust manifold Special tools and workshop equipment required

t  Engine bung set -VAS 6122-

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

–  Detach air cleaner cover -arrow-.

–  Remove bolts -arrows-. –  Remove air duct -1 and 2-.

–  Unplug electrical connectors: 1 -  On secondary air pump motor -V101- (vehicles with secondary air system) 2 -  On activated charcoal filter solenoid valve 1 -N80- 3 -  On output stage -N122- 4 -  On air mass meter -G70- 5 -  On charge pressure control solenoid valve -N75- –  Move wiring harness clear and lay on top of engine. –  Detach hose connections and remove air cleaner housing -arrows-.

–  Release fasteners -arrows- and remove noise insulation.

–  Loosen bolts -1- and -2- on support for turbocharger several turns.

–  Remove front hose from crankcase breather pipe -2-. Vehicles with secondary air system: –  Remove front hose from secondary air pipe -1-. All vehicles (continued): –  Remove heat shield -3-.

–  Unscrew bolts -1- and -2- for oil supply pipe. –  Remove bolts -3- for turbocharger. –  Detach gasket between turbocharger and exhaust manifold. –  Seal openings on turbocharger and all relevant ducts and hoses of the charge air system with plugs from engine bung set -VAS 6122-.

–  Remove nuts -arrows-. –  Detach washers and exhaust manifold. Installing   Note Renew gaskets and self-locking nuts. –  Fit exhaust manifold to cylinder head. –  Fit turbocharger to exhaust manifold. –  Fit bracket for turbocharger to cylinder block –  Fit bracket for turbocharger to turbocharger. Remaining installation steps are carried out in reverse sequence; note the following: –  Install air hoses with screw-type clips → Fig.. Tightening torques → Chapter