Left exhaust manifold with catalytic converter, removing and installing

WARNING: This page is about a different car, the 2010 Audi A8, 2009 Audi A8, 2008 Audi A8, and 2007 Audi A8. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

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Engine support bridge 10 - 222 A

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Adapter 10 - 222 A/21

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Tension strap T10038

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Engine Support Supplement Set T40093

Removing

NOTE:

During installation, all cable ties must be re-installed at the same location.

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Pull rear engine cover - arrows - off.
Drain coolant → Cooling system, draining and filling .
Remove left coolant pipe → Left coolant pipe, removing and installing .
Remove left front muffler → Left front muffler, removing and installing .

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Remove electrical harness connectors from bracket and disconnect it:

3 - For Heated Oxygen Sensor (HO2S) 2 G108

4 - For Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131

Free up electrical wires to oxygen sensors.

NOTE:

Ignore items - 1 and 2 -.

Remove left front wheel.
Remove front part of left front wheel housing liner → 66 - EXTERIOR EQUIPMENT .

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Remove bolt - arrow - at torque support mount.

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Remove bolt - arrow - and pull hydraulic oil pressure pipe forward slightly.
Remove nuts - 6 to 1 -.

NOTE:

To improve clarity, the engine is shown removed.
Nut - 1 - is accessible from wheel housing.

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Remove rubber seal - 1 - and remove plenum chamber covers - 2 and 3 -.

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Remove tower brace rear bolts - 3 -.
Secure Engine Support Bridge 10 - 222 A/21 with Adapter 10 - 222 A/4 at suspension strut towers.

Support for left and right side of vehicle is marked.
The middle contact point - 2 - of the support is placed on tower brace front bolts.
The Adapters 10 - 222 A/21 are secured with tower brace rear bolts - 3 -.
The knurled thumb screw - 1 - must be turned downward far enough so that the contact plate rests on strut tower.

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Install Adapter 10 - 222 A/4 with adapters T40093/6 on adapters 10 - 222 A/21.
Secure spindles 10 - 222 A/11 at engine lifting eyes.
Lightly tension engine with engine support bridge spindles.

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Remove left and right stabilizer bar mount bolts - 1 and 2 -.

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Remove bolts - 3 and 4 -.

NOTE:

Ignore items - 1 and 2 -.

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Remove bracket for noise insulation - arrows -.

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Remove drive shaft heat shield from transmission - arrows -.

NOTE:

To improve clarity, the engine is shown removed.

Remove left drive axle from transmission flange shaft.

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Remove front transmission mount left and right bolts - arrows -.

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Remove bolts - arrows - and remove transmission support with transmission mount.

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Identify installation position of selector lever cable bracket with a felt-tip pen for re-installation.
Press ball socket - 1 - of selector lever cable from selector shaft lever using pry lever 80 - 200.
Remove bolts - 2 - and lay aside selector lever cable.

NOTE:

Ignore - 3 -.

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Disconnect left and right electrical connector - 2 - on Level Control System Sensor.

NOTE:

Ignore - 1 -.

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Lower engine/transmission assembly by dimension - a - by rotating spindles 10 - 222 A/11.

Dimension - a - = 80 mm maximum.

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Remove bolts - 2 and 3 - and remove tab.

NOTE:

Ignore - 1 -.

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Pivot front of engine/transmission assembly slightly to right.
Loosen one bolt - arrow - from engine to transmission connection approx. 2 turns and loosen Tension Strap T10038 around bolt and around brace on right longmember.

CAUTION: Risk of damaging drive shaft boots.

Carefully guide left exhaust manifold with catalytic converter when removing.

Remove left exhaust manifold with catalytic converter toward rear.

Installing

Tightening torques → Engine, installing , → Exhaust manifold, assembly overview , → Left exhaust manifold tightening sequence , → Individual suspension components, left side , → Left drive shaft heat shield .

Installation is in reverse order of removal, note the following:

NOTE:

Replace gasket and self-locking nuts.

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Place new gasket onto stud bolts.
Insert exhaust manifold in securing strips and tighten → Left exhaust manifold tightening sequence
Install left drive axle → 40 - FRONT SUSPENSION .
Install transmission mount → 37 - CONTROLS, HOUSING .

Install torque support bracket → Assembly mount, overview .
Install subframe → 40 - FRONT SUSPENSION .
Install stabilizer bar → 40 - FRONT SUSPENSION .
Install left coolant pipe → Left coolant pipe, removing and installing .

Install left front muffler → Left front muffler, removing and installing .
Align exhaust system free of tension → Exhaust system, installing free of tension .
Fill with coolant → Filling .