Removing Rear Silencer - Turbo

Information 

Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:

• Torx screws: (E..) for external Torx, (T..) for internal Torx. 
• Hexagon-head bolts (internal and external hexagon): Wrench size (a/f) 

Component overview: 

Fig 1: Overview Of Exhaust System Without Manifold Component

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1. Rear silencer
2. Tailpipe cover
3. Catalytic converter
4. Clamp
5. Restraining strap
6. Cheese head bolt, M8 x 50
7. Rear silencer holder (with engine carrier bolted on)
8. Hexagon nut, M8 - always replace
9. Heat shield
10. Turbocharger
11. Metal seal
12. Position of restraining strap on holder

→ Let hot components cool down.

→ Wear personal protective gear.

1. Unscrew four M8 hexagon nuts (a/f 13) -1-  on the catalytic converter flange for the turbocharger on cylinder bank 1-3.
   Fig 2: Identifying Upper Turbocharger Flange Nuts (Cylinder Bank 1-3)

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   View of lower threaded joint:

   Fig 3: Identifying Lower Turbocharger Flange Nuts (Cylinder Bank 1-3)

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   1. 1.1. Remove heat shield on the catalytic converter.
2. Loosen rear silencer mounting.
   1. 2.1. Loosen clamp -1-  on the connection point between the rear silencer and catalytic converter (cylinder bank 4-6).
   2. 2.2. Loosen restraining straps. To do this, loosen two M8 cheese head bolts (hexagon socket a/f 6) -2-  .
      Fig 4: Identifying Rear Silencer Mounting

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   3. 2.3. Slide restraining straps out over the holder.
      Fig 5: Sliding Restraining Straps To Rear Silencer

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      Information 

      • The help of another person is required for removing and installing the silencer. 
3. Remove the rear silencer and catalytic converter with the help of another person.
   1. 3.1. Loosen the catalytic converter (cylinder bank 1-3) from the threaded bolts on the turbocharger -arrow 1-  and press it backwards.
   2. 3.2. Pull off the rear silencer and catalytic converter at the connection point for the catalytic converter on cylinder bank 4-6 -arrow 2-  .
      Fig 6: Removing Rear Silencer/Catalytic Converter (Cylinder Bank 1-3)

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4. Disconnect the removed rear silencer from the catalytic converter (cylinder bank 1-3).
   1. 4.1. To do this, loosen the clamp at the connection point between the rear silencer and catalytic converter.
5. Replace metal seal for turbocharger and four lock nuts.
6. Clean sealing faces and joints (on rear silencer and catalytic converter).