Audi Workshop Service and Repair Manuals

Removing and installing front exhaust pipe (left-side) with catalytic converter - vehicles with automatic gearbox 09L Special tools and workshop equipment required

t  Engine and gearbox jack -V.A.G 1383 A-

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 wire 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.

–  Unplug electrical connector -1- for Lambda probe 2 after catalytic converter -G131- and move wiring clear (downwards).   Note Disregard -item 2-.

–  Unscrew nut -2- (accessible from above) connecting front exhaust pipe to exhaust manifold.   Note Shown from rear with engine removed for illustration purposes. –  Remove front left wheel.

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

–  Open quick-release fasteners -1 … 3- and take off front and rear noise insulation.

–  Unbolt heat shield -arrows- for drive shaft (left-side). –  Detach drive shaft (left-side) from flange shaft of gearbox.

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

–  Remove bolts -1- and -2-. –  Detach bracket for front exhaust pipe.

–  Loosen clamps on exhaust system -arrows- and disconnect exhaust pipes.

–  Remove bolts -arrows- for gearbox mountings (left and right).

–  Apply lifting column of engine/gearbox jack -V.A.G 1383 A- centrally below cast lug on gearbox housing -arrow- and lift gearbox slightly.

–  Remove heat shield for gearbox support (left-side). –  Unbolt gearbox support (left-side) with gearbox mounting -arrows-. –  Raise gearbox carefully with engine/gearbox jack -V.A.G 1383 A- until it comes into contact with transmission tunnel (body). –  Guide out front exhaust pipe downwards between gearbox and subframe, turning as required. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets and self-locking nuts. t  Fit all cable ties in the original positions when installing. t  When installing, the Lambda probe wire must always be reattached at the same locations to prevent it from coming into contact with the exhaust pipe. –  Install gearbox support with gearbox mounting → Rep. Gr.37. –  Install drive shaft → Rep. Gr.40. –  Align exhaust system so it is free of stress → Chapter.   Note Mounting components for exhaust system → Fig.. Tightening torques

		Nm
Front exhaust pipe with catalytic converter to exhaust manifold		27 1)2)
Mounting plate to:	Front exhaust pipe	23
	Gearbox	25
Drive shaft heat shield to gearbox		25
l  1) Renew nuts. l  2) Grease with high-temperature paste; refer to → Electronic parts catalogue for high-temperature paste