Right 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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine support bridge 10 - 222 A

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Adapter 10 - 222 A/21

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drip tray for workshop crane VAS 6208

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine Support Supplement Set T40093

Removing

NOTE:

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

CAUTION: Risk of destroying electrical components when battery is disconnected.

Observe measures when disconnecting battery.

With ignition switched off, disconnect Battery Ground (GND) wire → 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove rear engine cover.
Drain coolant → Cooling system, draining and filling .
Remove right coolant pipe → Right coolant pipe, removing and installing .
Remove ribbed belt → Ribbed belt, removing and installing

Remove the generator → 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .
Remove right front muffler → Right front muffler, removing and installing .

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove electrical harness connectors from bracket and disconnect it:

For Heated Oxygen Sensor (HO2S) G39
For Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130

Free up electrical wires to oxygen sensors.

NOTE:

Ignore items - 3 and 4 -.

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolt - arrow - at torque support mount.

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows -.

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 the 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.

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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.

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 3 and 4 -.

NOTE:

Ignore items - 1 and 2 -.

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove engine bracket bolts at left and right - arrows -.
Remove engine carrier.

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

NOTE:

Ignore - 1 -.

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Dimension - a - = 30 mm maximum.

Remove torque support bracket.

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 2 to 5 -.
Remove torque support.

NOTE:

Ignore - 1 -.

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect right engine mount electrical connectors - 2 -.
Remove electrical wiring bracket from right engine support - 1 -.
Remove bolts - arrows - and remove engine support with engine mount.

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place drip tray for workshop crane VAS 6208 under engine.
Disconnect right coolant hose - arrow - and drain coolant.

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove nuts - 6 to 1 -.

NOTE:

Lower securing strips remain installed.

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolt - 2 - and remove right exhaust manifold from below with catalytic converter toward front.

NOTE:

Ignore - 1 -.

Installing

Tightening torques → Exhaust manifold, assembly overview , → Left exhaust manifold tightening sequence , → Individual components of suspension, right side .

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

NOTE:

Replace gasket and self-locking nuts.

Place new gasket onto stud bolts.

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert exhaust manifold in securing strips and tighten → Left exhaust manifold tightening sequence .
Install torque support and torque support bracket → Assembly mount, overview .
Install right front muffler → Right front muffler, removing and installing .
Install engine support with engine mount → Assembly mount, overview .

Install generator → 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .
Install ribbed belt → Ribbed belt, removing and installing .
Install subframe and engine carrier → 40 - FRONT SUSPENSION .
Install stabilizer bar → 40 - FRONT SUSPENSION .

Install right coolant pipe → Right coolant pipe, removing and installing .
Align exhaust system free of tension → Exhaust system, installing free of tension .
Observe safety precautions after connecting battery → 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .
Fill with coolant → Filling .