Audi Workshop Service and Repair Manuals

Removing and installing front exhaust pipe (left-side) with starter catalytic converter and main catalytic converter (vehicles with manual gearbox) Special tools and workshop equipment required

t  Hose clamps for hoses up to 25 mm Ø -3094-

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 fitted in the same position when installing. –  Pull off rear engine cover panel -arrows-.

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

–  Clamp off coolant hose -2- using hose clamp -3094- and detach from coolant expansion tank. –  Plug connection with a suitable plug. –  Unbolt coolant expansion tank -arrow-. –  Unplug electrical wire for coolant shortage indicator switch -F66- at expansion tank (bottom) and move expansion tank to one side (coolant hose -1- remains attached).

–  Remove electrical connectors -1 ... 4- from bracket (on left side of bulkhead). –  Unplug electrical connectors -1- and -4-. –  Unbolt bracket at bulkhead. –  Remove heat insulation sleeve at wiring harness and move wiring harness clear. –  Move clear Lambda probe wires downwards. –  Remove front wheel (left-side).

–  Release quick-fasteners -1-, unscrew bolts -2- and take off noise insulation.

–  Unbolt bracket for noise insulation -arrows-.   Note To avoid any damage, the flexible joint in the front exhaust pipe must not be bent more than 10°.

–  Disconnect exhaust system at clamp (left-side) -left arrow-.

–  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-.

–  Lower rear cross member slowly with engine and gearbox jack -V.A.G 1383 A- until the distance between rear cross member and body has reached dimension -x-. l  Dimension -x- = 60 mm.   Note The gearbox must NOT be lowered any further, as the propshaft joint and the flexible joint in front exhaust pipe could become damaged.

–  Unscrew heat shields for drive shafts (left and right-side) -arrow-.

–  Unscrew connecting rod -2- of selector rod. –  Unscrew hexagon socket head bolt for push rod -1-.

–  Detach Lambda probe wiring from gearbox at the points marked with -arrows-.   Note Illustration shows engine/gearbox assembly removed.

–  Unscrew bolt -arrow- at bracket for front exhaust pipe (left-side).

–  Unscrew nuts -1 ... 3- securing front exhaust pipe to exhaust manifold (left-side).   Note Illustration shows engine removed. –  Detach front exhaust pipe from 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  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. t  Fit all cable ties in the original positions when installing.

–  Tighten nuts -1 ... 3- securing front exhaust pipe/exhaust manifold evenly in stages; at the same time align the catalytic converter horizontally. –  Install subframe → Rep. Gr.40.   Note Mounting components for exhaust system on gearbox → Fig.. –  Align exhaust system so it is free of stress → Chapter. Tightening torques

Component	Nm
Front exhaust pipe with starter and main catalytic converter to exhaust manifold	27
Front exhaust pipe with starter and main catalytic converter to mounting bracket	25
Push rod to gearbox	40
Connecting rod for selector rod to gearbox	23
Shield for drive shaft to gearbox	23