Audi Engine 2.8 V6 5V AHA & ATQ service repair Manual

26-1 Exhaust system components, removing and installing WARNING! Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used only once, and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow the recommendations in this manual-replace these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection. Notes: Always replace gaskets and self-locking nuts. After exhaust system repairs, make sure exhaust system is not under stress and that it has sufficient clearance from the bodywork. If necessary, loosen double clamps and align muffler and and exhaust pipe so that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded. Page 1 of 12 Exhaust system components, removing and installing 11/21/2002 http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.GE03.26.1

The flexpipe in left and right exhaust pipes must not be bent more than 10 , otherwise it may be damaged. Page 2 of 12 Exhaust system components, removing and installing 11/21/2002 http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.GE03.26.1

26-2 Exhaust manifold, front exhaust pipe and Three Way Catalytic Converter (TWC) with attachments 1 - Spacer sleeve 2 - Bolt 3 - Washers 4 - Bracket 5 - Spacer bushing 6 - Rubber bushing 7 - 25 Nm (18 ft lb) 8 - Spring 9 - Bolt 25 Nm (18 ft lb) 10 - To center muffler Page 3 of 12 Exhaust system components, removing and installing 11/21/2002 http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.GE03.26.1

26-3 CAUTION! Part numbers are listed here for reference only. Always check with your Parts department for the latest information. 11 - Left-front exhaust pipe with Three Way Catalytic Converter (TWC) The flexpipe in left and right exhaust pipes must not be bent more than 10 , otherwise it may be damaged 12 - Heated Oxygen Sensor (HO2S) 2 -G108- 50 Nm (37 ft lb) Only grease threads using "G5" ("G5" must not get into slots on body of sensor) Checking DTC memory Repair Manual, 2.8 Liter V6 5V Fuel Injection & Ignition, Repair Group 01 Checking components and heating function Repair Manual, 2.8 Liter V6 5V Fuel Injection & Ignition, Repair Group 24 Page 4 of 12 Exhaust system components, removing and installing 11/21/2002 http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.GE03.26.1

26-4 13 - 4-pin harness connectors Black Mounted to bulkhead For Heated Oxygen Sensors (HO2S) and for heating function 14 - 25 Nm (18 ft lb) 15 - Cover cap 10 Nm (7 ft lb) 16 - Connection 17 - Upper heat shield 18 - Lower heat shield 19 - Left-side exhaust manifold 20 - Gaskets Always replace 21 - Right-side exhaust manifold Page 5 of 12 Exhaust system components, removing and installing 11/21/2002 http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.GE03.26.1

26-5 CAUTION! Part numbers are listed here for reference only. Always check with your Parts department for the latest information. 22 - Heated Oxygen Sensor (HO2S) -G39- 50 Nm (37 ft lb) Only grease threads with "G5" ("G5" must not get into slots on body of sensor) Checking DTC memory Repair Manual, 2.8 Liter V6 5V Fuel Injection & Ignition, Repair Group 01 Checking components and heating function Repair Manual, 2.8 Liter V6 5V Fuel Injection & Ignition, Repair Group 24 23 - Right-front exhaust pipe with Three Way Catalytic Converter (TWC) The flexpipe in left and right exhaust pipes must not be bent more than 10 , otherwise it may be damaged Page 6 of 12 Exhaust system components, removing and installing 11/21/2002 http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.GE03.26.1

26-6 Mufflers with mounts Vehicles with all-wheel drive Vehicles with front-wheel-drive page 26 - 9 . 1 - 40 Nm (30 ft lb) 2 - From Three Way Catalytic Converter (TWC) 3 - Carriage bolts 4 - Double clamp 5 - 25 Nm (18 ft lb) 6 - Mounts With retaining ring 7 - Center muffler 8 - Double clamp (for repair) Page 7 of 12 Exhaust system components, removing and installing 11/21/2002 http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.GE03.26.1

26-7 9 - Separating points At factory, center and rear mufflers are installed as single component. Replacement center and rear mufflers are supplied separately, with double clamp for connecting joint Cutting through at separating point Fig. 1 10 - Right-rear muffler 11 - Mounts 12 - Brackets 13 - Left-rear muffler Page 8 of 12 Exhaust system components, removing and installing 11/21/2002 http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.GE03.26.1

26-8 Cutting Fig. 1 Separating point between front and rear mufflers - Using VAG1523 body saw, cut through connecting pipe between center muffler and rear muffler at groove. Distance -a-: approx. 244 mm (9-1/2 in.). Page 9 of 12 Exhaust system components, removing and installing 11/21/2002 http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.GE03.26.1

26-9 Vehicles with front wheel drive 1 - 40 Nm (30 ft lb) 2 - From Three Way Catalytic Converter (TWC) 3 - Carriage bolts 4 - Double clamps 5 - 25 Nm (18 ft lb) 6 - Mounts With retaining ring 7 - Center muffler 8 - Bracket 9 - Mount 10 - Rear muffler 11 - Double clamp (for repair) Page 10 of 12 Exhaust system components, removing and installing 11/21/2002 http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.GE03.26.1

Audi Engine 2.8 V6 5V AHA & ATQ service repair Manual

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