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

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.

Special tools, testers and auxiliary items required

Fig 1: Identifying Engine/Transmission Jack V.A.G. 1383 A

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Engine/transmission jack V.A.G 1383 A

Removing

NOTE:

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

Fig 2: Removing Rear Engine Cover

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Remove rear engine cover - arrows -.

Fig 3: Removing Cover In Engine Compartment (Right Side)

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

Fig 4: Removing Air Guide Hose

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Remove air guide hose - arrows -.

Fig 5: Removing Bracket For Electrical Harness Connectors At Right From Bulkhead

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Remove harness connectors - 1 to 4 - from bracket at right of bulkhead.
Disconnect electrical harness connectors - 2 - and - 4 -.
Free up oxygen sensor wires downward.
Remove right front wheel.

Fig 6: Removing Quick-Release Fasteners, Screws And Noise Insulation

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

Fig 7: Removing Bracket For Noise Insulation

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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 8: Disconnecting Exhaust System At Double Clamps

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

Fig 9: Supporting Tunnel Cross Member Using VAG1383A Engine/Transmission Lift And A Piece Of Wood

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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 10: Identifying Distance Between Cross Member And Body Reaches Dimension

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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 11: Drive Axle Heat Shield

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Remove heat shield - arrow - for right drive axle.

Fig 12: Identifying Push Rod And Connecting Rod For Selector Rod

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

Fig 13: Freeing Up Oxygen Sensor Wires At Areas Indicated By On Transmission

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

NOTE:

Illustration shows engine/transmission assembly removed.

Fig 14: Removing Bolt At Strap For Right Front Exhaust Pipe

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

Fig 15: Removing Nuts For Right Front Exhaust Pipe/Exhaust Manifold

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

NOTE:

Illustration shows engine removed.

Remove front exhaust pipe with pre- and main catalytic converters.

Installing

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

NOTE:

Replace self-locking nuts.
Secure all hose connections using hose clamps appropriate for the model type .
During installation, all cable ties must be re-installed at the same location.

Fig 16: Removing Nuts For Right Front Exhaust Pipe/Exhaust Manifold

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Tighten nuts - 1 to 3 - of front exhaust pipe/exhaust manifold bolts uniformly in stages, align catalytic converter horizontally while doing so.
Install subframe → 40 - FRONT SUSPENSION .

NOTE:

Individual mounting components of exhaust system on transmission Individual components of suspension, right side

Align exhaust system free of tension → Exhaust system, installing free of tension .

Torque specifications

Component	Nm
Front exhaust pipe with pre- and main catalytic converters to exhaust manifold	27
Front exhaust pipe with pre- and main catalytic converters to mounting strap	25
Pivot rod on transmission	40
Shift rod connecting rod on transmission	23
Driveshaft guard on transmission	23