Left front exhaust pipe with primary and main catalytic converter (vehicles with manual transmission), removing and installing: Removing

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2009 Audi S4, 2008 Audi S4, 2007 Audi S4, 2006 Audi S4, and 2005 Audi S4. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

Fig 1: Removing Rear Engine Cover

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove rear engine cover - arrows -.

Fig 2: Removing Cover In Engine Compartment (Left Side)

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove cover - 1 - in engine compartment (left side).

Fig 3: Removing Coolant Hoses & Coolant Expansion Tank

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Clamp off coolant hose - 2 - using Hose clamps up to 25 mm diameter 3094 and disconnect from coolant expansion tank.
Seal connection using a plug that fits.
Remove coolant expansion tank - arrow -.
Disconnect electrical wire to Engine Coolant Level (ECL) Warning Switch F66 at bottom on expansion tank and set aside coolant expansion tank with coolant hose - 1 - connected.

Fig 4: Removing Bracket For Electrical Harness Connectors At Left From Bulkhead

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove electrical harness connectors - 1 to 4 - from bracket at left of bulkhead.
Disconnect electrical harness connectors - 1 - and - 4 -.
Remove bracket from bulkhead.
Remove heat insulation sleeve on wiring harness and lay open wiring harness.

Free up oxygen sensor wires downward.
Remove left front wheel.

Fig 5: Removing Quick-Release Fasteners, Screws And Noise Insulation

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove quick-release fasteners - 1 - , remove screws - 2 - and remove noise insulation.

Fig 6: Removing Bracket For Noise Insulation

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bracket for noise insulation - arrows -.

NOTE:

Flex joint in front exhaust pipe must not be bent more than 10 ° , otherwise it may be damaged.

Fig 7: Disconnecting Exhaust System At Double Clamps

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect exhaust system at left double clamp - left arrow -.

Fig 8: Supporting Tunnel Cross Member Using VAG1383A Engine/Transmission Lift And A Piece Of Wood

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place Engine/transmission jack V.A.G 1383 A plunger with a block of wood inserted in between - arrow - beneath rear cross member.
First remove bolts - 1 - and - 2 - , then bolts - 3 - and - 4 -.

Fig 9: Identifying Distance Between Cross Member And Body Reaches Dimension

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Slowly lower rear cross member using engine/transmission jack V.A.G 1383 A until distance between rear cross member/chassis acquires dimension - x -.

Dimension - x - = 60 mm.

NOTE:

Transmission must not be lowered further because otherwise driveshaft joint and decoupling element in front exhaust pipe may be damaged.

Fig 10: Drive Axle Heat Shield

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove heat shield for left and right drive axles - arrow -.

Fig 11: Identifying Push Rod And Connecting Rod For Selector Rod

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect connecting rod - 2 - of shift rod.
Remove socket head bolt of pivot rod - 1 -.

Fig 12: Freeing Up Oxygen Sensor Wires At Areas Indicated By On Transmission

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Free up oxygen sensor wires at areas indicated by - arrows - on transmission.

NOTE:

Illustration shows engine/transmission assembly removed.

Fig 13: Removing Bolt At Strap For Left Front Exhaust Pipe

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolt - arrow - at strap for left front exhaust pipe.

Fig 14: Removing Nuts For Left Front Exhaust Pipe/Exhaust Manifold

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove nuts - 1 to 3 - for left front exhaust pipe/exhaust manifold.

NOTE:

Illustration shows engine removed.

Disconnect front exhaust pipe from left exhaust manifold.
Remove front exhaust pipe with pre- and main catalytic converters.