Left 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.

Special tools, testers and auxiliary items required

Fig 1: Identifying Ring Spanner 7-Piece Set 3337

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Ring spanner 7-piece set for oxygen sensor 3337

Removing

NOTE:

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

Fig 2: Removing Rear Engine Cover

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Remove rear engine cover - arrows -.

Fig 3: Removing Coolant Hoses At Coolant Expansion Tank

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Remove coolant expansion tank - arrow -.
Disconnect electrical connection from Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant reservoir and set aside coolant reservoir with coolant hoses - 1 - and - 2 - connected.

Fig 4: Removing Nuts & Left Front Exhaust Pipe With Catalytic Converter

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Remove nut - 2 - of relevant threaded fastener for front exhaust pipe/exhaust manifold, which is accessible from top.

NOTE:

To improve clarity, the removed engine is shown from the rear.

Drain coolant → Cooling system, draining and filling .
Remove left front wheel.

NOTE:

Secure brake disc with a wheel bolt.

Fig 5: Removing Heat Shield For Left Drive Axle

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Remove heat shield - arrows - for left drive axle.

Fig 6: Removing Nuts & Left Front Exhaust Pipe With Catalytic Converter

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Remove nuts - 1 - and - 3 - which are accessible from bottom for front exhaust pipe/exhaust manifold.

NOTE:

To improve clarity, the removed engine is shown.

Fig 7: Locating Clamping Sleeves

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NOTE:

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

Disconnect exhaust system at clamping sleeve - left arrow -.
Push the clamping sleeve back and pull the front exhaust pipe off from the exhaust manifold.

NOTE:

The front exhaust pipe remains on vehicle.

Fig 8: Removing Bolts For Heat Shield

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Remove bolts - 3 - and - 4 - for heat shield, which are accessible from bottom.

Fig 9: Identifying Front Engine Cover

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Remove front engine cover - arrows -.

Fig 10: Removing Coolant Hose From Front Coolant Line

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Remove coolant hose - arrow - from front coolant line.

Fig 11: Removing Left Front Coolant Hose In Engine Compartment

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Remove left front coolant hose in engine compartment - arrows -.

Fig 12: Removing Coolant Hose From Front Coolant Line

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Remove coolant hose - arrow - from front coolant line.

NOTE:

Place a rag under hydraulic line to catch escaping hydraulic fluid.

Fig 13: Removing Hydraulic Pressure Line At Power Steering Pump

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Remove hydraulic pressure line - arrow - at power steering pump and set it aside on top of longitudinal member.

Fig 14: Disconnecting Electrical Harness Connector At Camshaft Position (CMP) Sensor 4 G301

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Disconnect electrical harness connector - arrow - at Camshaft Position (CMP) Sensor 4 G301.
Free up electrical wiring.

Fig 15: Removing Bolts For Heat Shield

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Remove bolts - 1 - and - 2 - for heat shield, which are accessible from top.
Remove heat shield.

Fig 16: Disconnecting Electrical Harness Connector For Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131

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Disconnect electrical harness connector - 2 - for Heated Oxygen Sensor (HO2S) 2 G108 and free up wire.

NOTE:

Ignore - 1 -.

Fig 17: Removing Oxygen Sensor Using Ring Spanner Set 3337

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Remove oxygen sensor - 1 - using ring spanner set 3337.

NOTE:

To improve clarity, the engine is shown removed.
Ignore - 2 -.

Fig 18: Removing Nuts, Bracket For Heat Shield & Exhaust Manifold

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Remove nuts - 1 - and - 8 - and remove bracket for heat shield.
Remove nuts - 2 through 7 - and - 9 - and remove exhaust manifold.

Installing

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

NOTE:

Replace gaskets, seals and 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 19: Exhaust Manifold Tightening Sequence

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

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

Install oxygen sensor → 24 - FUEL INJECTION SYSTEM .
Install left front exhaust pipe with catalytic converter: Vehicles with manual transmission → Left front exhaust pipe with catalytic converter (vehicles with manual transmission), removing and installing , vehicles with automatic transmission → Left 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 .
Fill with coolant → Cooling system, draining and filling .

Check power steering oil level and top off if necessary → 48 - STEERING .

Torque specifications

Component	Nm
Exhaust manifold to cylinder head	25 ¹⁾²⁾
Heat shield to heat shield bracket	10
Hydraulic pressure line to power steering pump	47
Heat shield for drive shaft to transmission	23
¹⁾ Replace nuts. ²⁾ Grease with hot bolt paste; hot bolt paste .