Right exhaust manifold, removing and installing

WARNING: This page is about a different car, the 2006 Audi A4, 2005 Audi A4, 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Removing

Remove right front exhaust pipe with catalytic converter. Refer to Right front exhaust pipe with catalytic converter, removing and installing (vehicles with manual transmission) , Right front exhaust pipe with catalytic converter, removing and installing (vehicles with automatic transmission 01J) and Right front exhaust pipe with catalytic converter, removing and installing (vehicles with automatic transmission 01V) .

Fig 1: Removing Threaded Connection At Heat Shield & Unscrewing Threaded Connection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove threaded connection -2- at heat shield which is accessible from bottom.
Unscrew threaded connection -1- which is accessible from top.

Fig 2: Removing Bolts At Lines Of Secondary Air Injection & Resonator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts -1- and -2- at secondary air injection lines.

NOTE: Resonator -4- remains installed with bolts -3- and -5-.

Fig 3: Identifying Bolts, Hose From Line Of Secondary Air Injection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts -1- and -3-.
Disconnect hose -4- from secondary air injection line.
Pull out guide tube for oil dipstick -2- toward top from oil pan (upper part) and swing it forward.
Remove heat shield.

Fig 4: Unscrewing Threaded Connection On Exhaust Manifold & Removing Nuts, Heat Shield Bracket & Exhaust Manifold

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unscrew threaded connection -1- on exhaust manifold which is accessible from top.
Remove nuts -2- from bottom and remove heat shield bracket.
Remove nut -3- and remove exhaust manifold.

Installing

Installation is reverse of removal, noting the following:

NOTE: Replace gaskets and self-locking nuts.

Replace O-ring at guide tube for oil dipstick and insert guide tube into hole in oil pan (upper part).
Install right front exhaust pipe with catalytic converter. Refer to Installing for vehicles with automatic transmission 01J or Installing for vehicles with automatic transmission 01V.
Align exhaust system free of stress. Refer to Exhaust system, aligning free of stress (vehicles with front wheel drive) or Exhaust system, aligning free of stress (vehicles with all wheel drive) .

Tightening torque

Component		Nm
Exhaust manifold to cylinder head		25
Heat shield to heat shield bracket		10
Tube for	M6	10
Secondary Air Injection	M8	25
Guide tube for oil dipstick to line for secondary air injection		10