Removing and installing exhaust system components — AUDI

ABC ACZ
Notes:

Always replace gaskets and self-locking nuts.
Following exhaust system assembly work, make sure exhaust system is not subject to torsion and that there is an adequate gap between exhaust system and body. If necessary, unfasten clamps and align silencers and exhaust pipes such that there is sufficient distance from body all round and that mountings are subject to uniform load.
Left mounting components for vehicles with manual gearbox
=> Fig.
26-8
.
Right mounting components for vehicles with manual gearbox/left and right mounting components for vehicles with automatic gearbox => Fig.
26-8
.
Removing and installing front cross piece for floor
=>Fig.
26-10
Removing and installing rear cross piece for floor
=>Fig.
26-10

Rubber mount
Check pre-tensioning
=>Stress-free alignment of exhaust system, Page
26-30

25 Nm
Front right exhaust pipe
Stress-free installation => Page
26-13
Stress-free alignment of exhaust system => Page
26-30

Sealing ring
Sensitive to impact; not to be dropped

27 Nm
Observe tightening sequence
=> Page
26-13

25 Nm
Replace

Gasket
Replace
Installation position: Connecting web faces downwards

Lambda probe, 55 Nm
Grease thread only with hot bolt paste G 052 112 A3; paste must not be allowed to come into contact with slits in probe body
Checking:

=> Injection and Ignition System; Repair Group 24; Checking Lambda control; Checking Lambda probe and signal wire
Injection and Ignition System
Checking Lambda control
Checking Lambda probe and signal wire

Exhaust manifold
Removing and installing left exhaust manifold => Page
26-17
Removing and installing right exhaust manifold => Page
26-25

Front left exhaust pipe
Stress-free installation => Page
26-13
Stress-free alignment of exhaust system => Page
26-30

25 Nm
Catalytic converter
Protect against jolts and impact
Aligning catalytic converter => Fig.
26-9

Front clamp
Installation position => Fig.
26-7
Before tightening, perform stress-free alignment of exhaust system
=> Page
26-30
Tighten bolted joints evenly to 40 Nm

40 Nm
Sealing ring
Sensitive to impact; not to be dropped

25 Nm
Replace

Rubber mount
Check pre-tensioning
=>Stress-free alignment of exhaust system, Page
26-30

Rear silencer
Combined with centre silencer as original equipment; replace separately when performing repair work
Cutting point => Page
26-11
Stress-free alignment of exhaust system => Page
26-30

Rear clamp
For separate replacement of centre and rear silencer
Installation position => Fig.
26-7
Before tightening, perform stress-free alignment of exhaust system=>Page
26-30
Tighten bolted joints evenly to 40 Nm

40 Nm
Centre silencer
Combined with rear silencer as original equipment; replace separately when performing repair work
Cutting point => Page
26-11
Stress-free alignment of exhaust system => Page
26-30

Rubber mount
Check pre-tensioning
=>Stress-free alignment of exhaust system, Page
26-30

Fig.1
Installation position of front clamp

Fit clamp such that it is horizontal.
Bolted joint faces left
a = 30°
b = 25 ... 30 mm

Fig.2
Installation position of rear clamp

Bolted joint faces right
a = 30°

Fig.3
Left mounting for vehicles with manual gearbox

1 -
Bolt, 25 Nm
2 -
Gearbox
3 -
Front left exhaust pipe
4 -
Self-locking nut, 25 Nm

Fig.4
Right mounting for vehicles with manual gearbox/left and right mounting for vehicles with automatic gearbox

1 -
Gearbox
2 -
Self-locking nut, 25 Nm
3 -
Front right exhaust pipe
4 -
Self-locking nut, 25 Nm

Fig.5
Gap between front exhaust pipes and front cross piece for floor

Dimension a = 40 mm

Fig.6
Aligning catalytic converter

Align catalytic converter such that gap -a- on left is equal to gap -a- on right.

Fig.7
Removing and installing front cross piece for floor

On installation, tighten bolts -arrows- to 25 Nm.

Fig.8
Removing and installing rear cross piece for floor

On installation, tighten bolts -arrows- to 25 Nm.