Left Exhaust System Tract, Removing and Installing

WARNING: This page is about a different car, the 2009 Audi S8, 2008 Audi S8, and 2007 Audi S8. However, it is still accessible from the selected car via links, so may be relevant.

Removing

NOTE:

During installation, reinstall all heat insulation sleeves and heat shields at the same locations.
All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

Remove engine → Engine, Removing .
Leave engine with transmission installed on the scissor lift platform VAS 6131 A.

Fig 1: Oxygen Sensor Electrical Connectors & Tunnel Cross Member Bolts

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Remove electrical connector - 1 - for Oxygen Sensor (O2S) 3 Behind Three Way Catalytic Converter (TWC) G287 from bracket and disconnect it.

NOTE:

Ignore - 2 - and - arrows -.

Fig 2: Subframe Oxygen Sensor Electrical Connectors

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Remove bracket for oxygen sensor electrical connectors - 1 to 4 - from subframe - arrow -.
Remove electrical connectors - 1 - for Oxygen Sensor (O2S) 4 Behind Three Way Catalytic Converter (TWC) G288 and - 2 - for Heated Oxygen Sensor (HO2S) 3 G285 (in front of catalytic converter) from bracket on transmission and disconnect them.

Fig 3: Removing Bolts, Oil Dipstick Guide Tube Upward & Loosening Hose Clamps And Removing Left Coolant Pipe From Coolant Hoses

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Remove bolts - 2 - and - 3 -.
Pull oil dipstick guide tube upward and off - arrow -.

NOTE:

Ignore - 1 - and - 4 -.

Fig 4: Removing Bolt At Left Exhaust Tract Strap

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Remove bolt - arrow - at left exhaust tract strap.

Fig 5: Removing Nuts

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Remove nuts - arrows -.

Fig 6: Removing/Installing Nuts In Sequence And Left Front Exhaust Manifold With Catalytic Converter

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove nuts in sequence - 9 to 1 - and remove left front exhaust manifold with catalytic converter.

Fig 7: Oxygen Sensor Electrical Connectors

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connector - 1 - for Heated Oxygen Sensor (HO2S) 4 G286 and free up oxygen sensor wiring.

NOTE:

Ignore - 2 -.

Fig 8: Removing Nuts In Sequence And Left Rear Exhaust Manifold With Catalytic Converter

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Remove nuts in sequence - 6 to 1 - and remove left rear exhaust manifold with catalytic converter.

Installing

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

NOTE:

Replace gaskets, O-rings and self-locking nuts.
Secure all hose connections with hose clamps appropriate for the model .
During installation, reinstall all heat insulation sleeves and heat shields at the same locations.
During installation, all cable ties must be re-installed at the same location.

Fig 9: Removing Nuts In Sequence And Left Rear Exhaust Manifold With Catalytic Converter

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Position left rear exhaust manifold with catalytic converter on cylinder head and tighten nuts by hand.
Tighten left rear exhaust manifold nuts in 2 stages as follows:

Pre-tighten nuts in sequence 1 to 6 to 10 Nm. Pre-tighten nuts in sequence 1 to 6 to 25 Nm.

Fig 10: Removing/Installing Nuts In Sequence And Left Front Exhaust Manifold With Catalytic Converter

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Position left front exhaust manifold with catalytic converter on cylinder head and tighten nuts by hand.
Tighten left front exhaust manifold nuts in 2 stages as follows:

Pre-tighten nuts in sequence 1 to 9 to 10 Nm. Pre-tighten nuts in sequence 1 to 9 to 25 Nm.

Install engine → Engine, Installing .
Align exhaust system free of tension → Exhaust System, Installing .

Tightening Specifications

Component		Nm
Front exhaust manifold with catalytic converter to cylinder head		25 1)2)3)
Rear exhaust manifold with catalytic converter to	Cylinder Head	25 1)2)3)
	Y pipe	23
Y pipe to strap		23
Coolant pipe to cylinder head		9
1) Replace nuts. 2) Grease with hot bolt paste; Hot bolt paste . 3) Tighten in 2 stages.