Removal of exhaust manifold — AUDI

AEC AHK
The operations described below should be carried out for removing both exhaust manifolds.

Take off noise insulation panel (arrows indicate bolted connections).
Unbolt exhaust manifold from front exhaust pipe. Remove bolts from the exhaust manifolds.

Note:

The tapered seals are very sensitive to shocks; do not drop them.

Unbolt bracket for air guide pipes on left and right.
Remove air guide pipes.
Remove dome strut.

Unscrew top part of air filter housing (4 screws on the housing, 3 screws at rear of the housing).

Remove heat shield on left and right.

The operations described below should be carried out for removing the right-hand exhaust manifold only.

Unbolt the fixture for the electric connections from the side panel of the engine.

Attach lifting device into mounting hole at the rear right of the engine (lifting device is shown attached at the front left in the illustration to simplify the presentation).
Raise engine-gearbox unit carefully (about 10 mm at the suspension point).
Unbolt exhaust manifold and lift up and out of the vehicle.

The operations described below should be carried out for removing the left-hand exhaust manifold.

Unscrew and pull out guide tube for dipstick.

Slacken ribbed belt; to do so, firmly press down belt at bottom in centre by hand and insert setting pin 3204.
Remove belt.

Unbolt AC compressor (pay attention to dowel sleeves).
Unplug the connectors of the electrical connections for the compressor.
Allow AC compressor to hang down out of the vehicle (pipe/wiring remain connected).

Use hose clamp 3094 to pinch off suction hose of the power-steering pump reservoir.

Unbolt ribbed belt pulley. Counterhold with two-hole nut turning tool 3212.
Unbolt hydraulic pump from its fixture and allow to hang down out of the vehicle. Expansion hose remains connected.

Unscrew bracket for AC compressor and hydraulic pump.

Attach lifting device into mounting hole at the front left of the engine.
Raise engine-gearbox unit carefully (about 10 mm at the suspension point).
Unbolt exhaust manifold and lift up and out of the vehicle.

Installing exhaust manifold is carried out in reverse order of removal.

When installing compressor and hydraulic pump fit alignment gauge 3201 onto the belt pulley of the AC compressor.
The belt pulley of the hydraulic pump should be aligned with the belt pulley of the AC compressor.

Unscrew belt pulley for vane pump. Use the shims available in the Parts Programme to ensure that both belt pulleys are properly aligned.