Exhaust manifold, removing and installing: Removing

WARNING: This page is about a different car, the 2006 Audi A4, 2005 Audi A4, 2004 Audi A4, and 2003 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Always replace gaskets and self-locking nuts.
To avoid damage, do not bend decoupling element of front exhaust pipe by more than 10 °.

Fig 1: Removing Engine Cover

GW00017273

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove engine cover - arrows -.

Fig 2: Air Cleaner Cover

GW00004731

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove air cleaner cover - arrow -.

Fig 3: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct

GW00004732

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows -.
Disengage EVAP canister purge regulator valve N80 - 1 - from air duct - 2 -.
Remove both screws - arrows - for air duct - 2 -.

Fig 4: Disconnect Wires/Unplug Connectors From

GW00017291

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect wiring connectors from:

EVAP valve
Mass Air Flow sensor
Wastegate bypass regulator valve N75

Disconnect hoses -4 to 7-.

Fig 5: Disconnect Wires/Unplug Connectors From

GW00017291

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect hose to secondary air injection pump motor - 8 -.
Move wiring clear.
Unbolt air cleaner housing - 9 -.
Remove air cleaner.

NOTE:

Vacuum line to secondary air combination valve is clipped to underside of air intake hose.

Fig 6: Noise Insulation Tray Retainers

GW00005845

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove sound insulation - arrows -.

Fig 7: Locating Bolts On Turbocharger Bracket

GW00017356

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen bolts - 1 - and - 2 - a few turns.

Fig 8: Pulling Front Hose Off Crankcase Breather Line, Front Hose Off Line To Secondary Air Combination Valve & Removing Heat Shield

GW00017416

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull front hose off crankcase breather line - 2 -.
Pull front hose off line to secondary air combination valve - 1 -.
Remove heat shield - 3 -.

Fig 9: Removing Bolts Of Oil Supply Line & For Turbocharger

GW00017353

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 1 - and - 2 - of oil supply line.
Remove bolts - 3 - for turbocharger.
Remove gasket between turbocharger and exhaust manifold.
Plug opening in turbocharger with clean cloth.

Fig 10: Removing All Nuts On Exhaust Manifold

GW00017417

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove all nuts - arrows - on exhaust manifold.
Remove washers and exhaust manifold.