Audi Workshop Service and Repair Manuals

Removing and installing front exhaust pipe (left-side) with catalytic converter - vehicles with multitronic gearbox 01J Special tools and workshop equipment required

t  Lambda probe open ring spanner set -3337-

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

Removing –  Pull off engine cover panel (rear) -arrows-.

–  Remove cover -1- at right of engine compartment.

–  Unbolt retaining plate -3- for solenoid valves -arrows-. –  Detach air intake hose -1- at air mass meter -G70-. –  Disconnect crankcase breather hose -4- at air duct -2-.

–  Unscrew bolt -arrow- and pull air duct -2- off throttle valve module -J338-. –  If fitted, disconnect hose -1- from air duct.   Note Shown from rear with engine removed for illustration purposes.

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

–  Unbolt coolant expansion tank -arrow-. –  Unplug electrical connector for coolant shortage indicator switch -F66- at expansion tank (bottom) and tie expansion tank to one side (coolant hoses -1 ... 3- remain attached).

–  Disconnect vacuum line leading to brake servo -arrows-.

–  If fitted, remove heat shield for connections from bulkhead (left-side). –  Remove electrical connectors -1 ... 4- from bracket (at left on bulkhead). –  Unplug electrical connectors -1- and -4-. –  Move electrical wiring to Lambda probes clear.

–  Unscrew Lambda probe 2 after catalytic converter -G131--arrow- using tool from Lambda probe open ring spanner set -3337/7-.   Note Shown in illustration with engine removed.

–  Unscrew nut -2- (accessible from above) securing front exhaust pipe to exhaust manifold.   Note Shown in illustration with engine removed.

–  Remove front left wheel. –  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.

–  Unscrew bolts -1 … 4- and remove front cross-piece.   Note

To avoid any damage, the flexible joint in the front exhaust pipe must not be bent more than 10°. –  Loosen both clamps on exhaust system -arrows- and disconnect exhaust pipes.

–  Position lifting column of engine and gearbox jack -V.A.G 1383 A- underneath cross member (rear) with a piece of wood -1- placed in between.

–  First unscrew bolts -1- and -2-, then bolts -3- and -4-. –  Carefully lower rear tunnel cross member using engine and gearbox jack -V.A.G 1383 A-. –  Re-position engine and gearbox jack -V.A.G 1383 A-.

–  Unscrew nuts -arrows- and remove rear tunnel cross member.

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

–  Unbolt mounting plate for front exhaust pipe -arrows-. –  Expose Lambda probe wiring.

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

–  Unscrew nuts (bottom) -1- at engine mountings (right and left) several turns. –  Press gearbox to the right. –  Remove front exhaust pipe with catalytic converter. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets and self-locking nuts. t  Threads of new Lambda probes are already greased with assembly paste; the paste must not get into the slots on the probe body t  When re-using the old Lambda probe, grease thread with high-temperature lubricant; the paste must not get into the slots of the probe body; High-temperature lubricant → Parts catalogue. t  Fit all cable ties in the original positions 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. –  Install subframe → Rep. Gr.40. –  Align engine so it is free of stress. –  Align exhaust system so it is free of stress → Chapter.   Note Components of exhaust pipe mountings on gearbox for vehicles with multitronic gearbox 01J → Fig.. Tightening torques

Component		Nm
Front exhaust pipe with catalytic converter to:	Exhaust manifold	27
	Mounting plate	25
Mounting plate to gearbox		25
Lambda probe to catalytic converter		55
Engine mounting to console		23
Drive shaft heat shield to gearbox		23
Front cross member to body		55