Audi Workshop Service and Repair Manuals

Removing and installing exhaust manifold

Removing –  Remove engine cover panel -1-. –  Remove air cleaner cover -2-.

–  Unscrew bolts -arrows-. –  Remove air ducts -1- and -2-.

–  Unplug electrical connectors -3- and -5- for active charcoal filter system solenoid valve 1 -N80- and air mass meter -G70-. –  Detach active charcoal filter system solenoid valve 1 -N80--item 2- from air cleaner housing. –  Disconnect hose connection going to secondary air pump -arrow-. –  Release hose clip -4- for air pipe at air mass meter. –  Unscrew bolt -1- and remove air cleaner housing.

–  Detach hose -2- leading to exhaust gas recirculation valve -N18-. –  Detach crankcase breather hose -4- from air pipe. –  Loosen hose clip -3- to remove air pipe.   Note Disregard -item 1-.

–  Unscrew nuts -arrows- of bolt connection at catalytic converter/exhaust manifold.

–  Remove noise insulation -arrows-.

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

–  Unbolt bracket for exhaust system -arrow-.   Note

To avoid any damage, the flexible joint in the front exhaust pipe must not be bent more than 10°. –  Separate exhaust system at clamp -arrows-. –  Detach catalytic converter from exhaust manifold.

–  Remove connecting pipe for exhaust gas recirculation by unscrewing connections -1- and -2-. –  Unscrew nuts -arrows- and remove exhaust manifold. Installing Installation is carried out in the reverse order; note the following:   Note Renew gaskets and self-locking nuts. –  Install front exhaust pipe together with catalytic converter → Chapter. –  Align exhaust system free of stress → Chapter. Tightening torques

Component		Nm
Exhaust manifold to cylinder head		25 1)2)
EGR connecting pipe to	exhaust manifold	30
	connection	10
l  1) Renew self-locking nuts. l  2) Coat with high-temperature paste; refer to → Parts catalogue.