Removing and installing exhaust system, ABH — AUDI

AEC AHK
Notes:

Align exhaust system free of stress, =>Page
26-9
Checking exhaust system for leaks
=>Page
26-11
Joint between centre and rear silencer
=>Page
26-6
Fig.
1
Renew all gaskets and hexagon nuts.
Ensure that the load is evenly distributed over the hangers of the exhaust system.
Aligning flange connections of the exhaust system =>Fig.
26-7

Exhaust manifold

Hexagon nut
25 Nm

Exhaust manifold gasket
Insert beading in exhaust manifold groove

Heat shield
Plate nut, 1.5 Nm

Seals
Front exhaust pipe
Spring washers
Installing spring washers => Fig.
26-8

Hexagon nut 25 Nm

Warning!
The flange connections of the exhaust manifold/front exhaust pipe should be retightened to the specific torque of 25
Lambda probes, 50 Nm
Testing

=> Motronic fuel injection and ignition system; Repair Group 24; checking Lambda control
Motronic fuel injection and ignition system
checking Lambda control

Grease thread with G5. Keep grease away from slits in probe body.

Temperature sensor 30 Nm

Twin clamps
Tighten evenly, 40 Nm
Installation position =>Page
26-11
Always replace after unfastening union.

Hexagon nut 25 Nm
Rear silencer
Adjusting => Page
26-10
Aligning tail pipes=> Page
26-10

Retaining ring
Bracket for rear silencer
Hexagon nut 25 Nm

Centre silencer
Setting prestress of exhaust system => Page
26-9

Retaining ring
Hexagon nut 25 Nm
Catalytic converter
Adjusting => Fig.
26-7
Lock not of CO sampling connection 25 Nm

Oil seal
Catalytic converter mounting
Component layout =>Fig.
26-8

Heat shield
Hexagon nut 3 Nm

Fig.1
Joint between centre and rear silencer

A joint is provided for replacing the centre/rear silencer.

Dimension -a- 126.5 mm

Dimension -b- 142 mm

Two short double clips are provided for connecting the centre silencer and the tail silencer when carrying out repairs.
Twin clamps are to be installed horizontally.
Aligning tail pipes =>Page
26-10
.
Rear silencer alignment, => Page
26-10

Fig.2
Aligning catalytic converters

Dimension a = · 11 mm
Dimension b = · 183 mm
Dimension c = · 176 mm

Note:

The exhaust system is shown looking from the rear toward the catalytic converters.
The measurements should be carried out in the middle -d- of the catalytic converter collision guard.
The dimension between cross member and exhaust pipe should be 30 - 40 mm.

Fig.3
Aligning flange connections of the exhaust system

The bolted connections at the flanges of the exhaust system should be tightened in such a way that the flanges have the same clearance to each other -a- all round.

Fig.4
Catalytic converter mounting

Component layout

1 -
Hexagon bolt
2 -
Rubber bush
3 -
Spacer
4 -
Plate
5 -
Hexagon nut, 25 Nm
6 -
Hexagon bolt
7 -
Washer
8 -
Pressure spring
9 -
Spacer sleeves
10 -
Catalytic converters
11 -
Hexagon nuts, 25 Nm

Fig.5
The spring washers should be installed as shown in the illustration.