Right exhaust manifold, removing and installing

WARNING: This page is about a different car, the 2009 Audi A4, 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Removing

NOTE:

All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

Remove right front exhaust pipe with catalytic converter: Vehicles with manual transmission → Right front exhaust pipe with catalytic converter (vehicles with manual transmission), removing and installing , vehicles with automatic transmission → Right front exhaust pipe with catalytic converter (vehicles with automatic transmission 09L), removing and installing .

Fig 1: Placing Lifting Surface Of Engine/Transmission Jack V.A.G 1383 A Centrally On Lower Housing Base

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Vehicles with automatic transmission:

NOTE:

After removing right front exhaust pipe, the rear of the subframe is loosened.
The transmission is supported by the Engine/Transmission Jack V.A.G 1383 A centrally on lower housing base - arrow -.

Lift transmission slightly using Engine/Transmission Jack V.A.G 1383 A.

Fig 2: Removing Bolts And Mounting Bolts Of Subframe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install bolts - 1 - and - 4 - to hand-tight.

NOTE:

Ignore - 2 - and - 3 -.

Lower transmission and pull Engine/Transmission Jack V.A.G 1383 A out from under vehicle.

All:

Fig 3: Removing Bolts For Heat Shield

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 1 - and - 4 - for heat shield, which are accessible from bottom.

Fig 4: Identifying Bolts & Air Duct

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows -.
Remove air duct - 1 - and - 2 -.

Fig 5: Removing Pin From Spreader Clips

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove pin from spreader clips - arrow -.
Remove air filter housing.
Free up electrical wiring harness for generator and starter at longitudinal member.

Fig 6: Disconnecting Electrical Harness Connector At Camshaft Position (CMP) Sensor 3 G300

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - arrow - at Camshaft Position (CMP) Sensor 3 G300.
Free up electrical wiring.

Fig 7: Disconnecting Electrical Harness Connector For Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - 1 - for Heated Oxygen Sensor (HO2S) G39 and free up wire.

NOTE:

Ignore - 2 -.

Fig 8: Removing Bolts For Heat Shield

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 2 - and - 3 - , which are accessible from above, and remove heat shield.

Fig 9: Removing Nuts, Bracket For Heat Shield & Exhaust Manifold

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove nuts - 7 - and - 9 - and remove bracket for heat shield.
Remove nuts - 1 through 6 - and - 8 - and remove exhaust manifold.

Installing

Installation is in reverse order of removal, noting following:

NOTE:

Replace gaskets and self-locking nuts.
During installation, all cable ties must be re-installed at the same location.

Fig 10: Exhaust Manifold Tightening Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fasten exhaust manifold together with heat shield bracket in 2 steps according to indicated tightening sequence, as follows.

Pre-tighten to 15 Nm.
Tighten to 25 Nm.

Install right front exhaust pipe with catalytic converter: Vehicles with manual transmission → Right front exhaust pipe with catalytic converter (vehicles with manual transmission), removing and installing , vehicles with automatic transmission → Right front exhaust pipe with catalytic converter (vehicles with automatic transmission 09L), removing and installing .
Align exhaust system free of tension → Exhaust system, installing free of tension .

Torque specifications

Component	Nm
Exhaust manifold to cylinder head	25 ¹⁾²⁾
Heat shield to heat shield bracket	10
Hose clamps 9 mm wide	3
¹⁾ Replace nuts. ²⁾ Grease with hot bolt paste; hot bolt paste .