Installing exhaust system stress-free - vehicles with front-wheel drive — AUDI

Note:

The exhaust system must be aligned when cold.

Centre and rear silencers installed.
Mountings for exhaust system to gearbox installed => Fig.
26-7
.

Release the following bolted connections to the point at which the relevant exhaust system components can move in relation to each other:

-
Front exhaust pipe/exhaust manifold (left and right)
-
Exhaust system intermediate pipe/catalytic converter (left and right)
-
Front clamps
-
Flange between centre and rear silencers

Align the catalytic converters to dimensions -a...c-.
Dimension a = 8 ... 12 mm
Dimension b = 174 ... 179 mm
Dimension c = 163 ... 168 mm

Notes:

The measurements should be carried out in the middle -d- of the catalytic converter collision guard.
Illustration shows rear view of catalytic converters.

Vehicles with manual gearbox:

Tighten bolts -1...3- on left and then on right front exhaust pipe to 10 Nm initially, then tighten to their final tightening torque of 30 Nm in the same sequence.

Vehicles with automatic gearbox:

Tighten bolts -1...3- on left and then on right front exhaust pipe to 10 Nm initially, then tighten to their final tightening torque of 30 Nm in the same sequence.

Align intermediate pipes so that the measuring angles of the intermediate pipes are horizontal and at the same height -arrow A-.

Note:

The bump stop -D- must not be damaged. The exhaust system must not be resting on the bump stop.

Distances from buffer stop -D-:

Dimension b = 15 mm

Distance from cross-piece:

Dimension c = 70 mm

Align front silencer.
Dimension A = approx. 24 mm
Dimension B = approx. 25.5 mm
Dimension C = 7 ... 9 mm

Tighten the bolted connection at the catalytic converter/intermediate exhaust pipe flange connection (left and right) initially only hand-tight. The flange projections must be the same distance apart all the way round.
Dimension a at bottom = dimension a at top

Check the location of the centre silencer with respect to the stop buffer (bolted onto the crossmember).
Dimension A = 18 ... 24 mm

Check that the bolted connections on the flange between centre and rear silencer are parallel to the brake pressure regulator bracket.
Dimension a at bottom = dimension a at top

Tighten bolted connections at flange between centre and rear silencers (25 Nm).

Align clamps as follows:

The bolted connections of left clamp point to left.
Dimension c = 25 ± 5 mm
Angle d = 41°

The bolted connections of right clamp point to right.
Angle a = 60°
Dimension b = 25 ± 5 mm

Tighten the bolted connection at the catalytic converter/intermediate exhaust pipe flange connection (left and right) to final tightening torque (25 Nm).

Push exhaust system towards front of vehicle until front mounting of centre silencer is preloaded by a = 7 ... 9 mm.
Tighten front bolted connections on clamp evenly to 40 Nm.

Notes:

The securing tabs at the brackets should be bent over about 90° after installing the retainers.
The distance -b- between the retainer and the locking tabs should be at least 2 mm.

Aligning tailpipes

Align tailpipes so that distance -a- is the same on both sides.
At the same time, distance -b- must be obtained between bumper cut-out and tailpipe:
Dimension b = approx. 38 mm