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Removing and installing front exhaust pipe (right-side) with starter catalytic converter and main catalytic converter > < Separating centre and rear silencers

A4 Mk2

Removing and installing front exhaust pipe (left-side) with starter catalytic converter and main catalytic converter
Removing and installing front exhaust pipe (left-side) with starter catalytic converter and main catalytic converter
Special tools and workshop equipment required
   
t  Engine and gearbox jack -V.A.G 1383 A-
Removing
  Note
t  Fit all heat shields and heat insulation sleeves in the original positions when installing.
t  All cable ties which are released or cut open when removing must be fitted in the same position when installing.
  Note
  W00-0120
To avoid any damage, the flexible joint in the front exhaust pipe must not be bent more than 10°.
–  Separate exhaust system at clamps -1- and -2-.
  A26-10238
–  Position lifting column of engine and gearbox jack -V.A.G 1383 A- at cross member (rear) with a piece of wood -arrow- placed in between.
–  First unscrew bolts -1- and -2-, then bolts -3- and -4-.
  A34-0493
–  Lower rear cross member slowly with engine and gearbox jack -V.A.G 1383 A- until distance between rear cross member and body reaches dimension -x-.
l  Dimension -x- = 60 mm (maximum).
  Note
The dimension -x- must NOT be exceeded as this could damage the propshaft joint and bulkhead wiring or other connections.
  A26-0684
–  Remove electrical connectors -3- and -4- from bracket on gearbox.
–  Unplug electrical connectors.
–  Detach heat insulation sleeve at wiring harness and release individual electrical wires.
  A24-10167
–  Unscrew bolt -1- at bracket for front exhaust pipe (left-side).
  Note
Disregard -item 2-.
  A26-10239
–  Unscrew nuts -arrows- securing front exhaust pipe to exhaust manifold (left-side).
–  Take out front exhaust pipe with starter and main catalytic converter.
Installing
Installation is carried out in the reverse order; note the following:
  Note
t  Renew self-locking nuts.
t  Fit all heat shields and heat insulation sleeves in the original positions when installing.
t  Fit all cable ties in the original positions when installing.
  A26-10240
–  Tighten nuts -arrows- for front exhaust pipe/exhaust manifold bolt connection evenly in stages; at the same time align the main catalytic converter horizontally.
–  Install subframe with cross member → Rep. Gr.40.
  Note
Mounting components for exhaust system on gearbox → Fig..
–  Align exhaust system so it is free of stress → Chapter.
Tightening torques
  A26-10240
ComponentNm
Front exhaust pipe with starter catalytic converter and main catalytic converter to:Exhaust manifold25 1)
Mounting plate25
l  1) Renew nuts.

   

Removing and installing front exhaust pipe (right-side) with starter catalytic converter and main catalytic converter > < Separating centre and rear silencers