Left front exhaust pipe with primary and main catalytic converter (vehicles with automatic 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 Hose Clamps 3094

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Hose clamps up to 25 mm diameter 3094

Fig 2: Identifying Engine/Transmission Jack V.A.G. 1383 A

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Engine/transmission jack V.A.G 1383 A

Removing

NOTE:

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

Fig 3: Removing Rear Engine Cover

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Remove rear engine cover - arrows -.

Fig 4: Removing Cover In Engine Compartment (Right Side)

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

Fig 5: Removing Air Guide Hose

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Remove air guide hose - arrows -.

Fig 6: Removing Cover In Engine Compartment (Left Side)

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

Fig 7: Removing Coolant Hoses & Coolant Expansion Tank

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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 8: Removing Bracket For Electrical Harness Connectors At Left From Bulkhead

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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 9: 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 10: Disconnecting Exhaust System At Double Clamps

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NOTE:

Decoupling elements in front exhaust pipes must not be bent more than 10 ° danger of damage.

Disconnect exhaust system at double clamps - arrows -.

Fig 11: Removing Heat Shield For Driveshaft

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Remove heat shield - A - for driveshaft - arrows -.
Remove bolts at transmission/driveshaft flange.
Push driveshaft together with rear final drive. The constant velocity (CV) joints can move axially.
Tie up drive shaft to body.

Fig 12: Placing Lifting Surface Of Engine/Transmission Jack V.A.G 1383 A Centered On Housing Casing And Support Transmission From Below

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Place lifting surface of Engine/transmission jack V.A.G 1383 A centered on housing casing - arrow - and support transmission from below.

CAUTION: The lock carrier must be installed.

Fig 13: Removing Bolts And Mounting Bolts Of Subframe

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First remove bolts - 2 - and - 3 - and then mounting bolts - 1 - and - 4 - of subframe.

Fig 14: Lowering Engine/Transmission Assembly Using Scissor Lift Platform VAS 6131 Only Approx. By Dimension

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Lower transmission and subframe using Engine/transmission jack V.A.G 1383 A to dimension - a -.

Dimension - a - = 50 mm.

Fig 15: Removing Heat Shield For Left Drive Axle

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Remove heat shield - 1 - for left drive axle.

Fig 16: 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 17: Removing Bolt At Strap For Left Front Exhaust Pipe

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

Fig 18: Removing Nuts For Left Front Exhaust Pipe/Exhaust Manifold

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

NOTE:

Illustration shows engine/transmission assembly 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.
During installation, re-install all heat insulation sleeves at the same locations.
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: Removing/Installing Nuts For Left 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 left mounting components - vehicles with automatic transmission

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
Heat shield for drive shaft to transmission	23