Left Front Exhaust Pipe W/Converter, Removing and Installing

Left Front Exhaust Pipe With Catalytic Converter, Removing And Installing

NOTE:
- Replace gaskets and self-locking nuts.
- Decoupling element in front exhaust pipe must not be bent more than 10 degree, otherwise it may be damaged..

Removing







- Remove the center engine cover (arrows).
- Remove cover -2- above the left cylinder head.







- Remove the air intake tube (arrows) between the air filter and the throttle valve part.







- Disconnect the electrical harness connector -2- for oxygen sensor behind catalytic converter and expose wire.

NOTE: Secure a binding wire to connector for oxygen sensor behind catalytic converter to facilitate pulling in the wire during installation.







- Remove coolant reservoir -3- (arrows)
- Disconnect wire from Engine Coolant Level (ECL) Warning Switch - F66- and lay coolant reservoir to side.

NOTE: Coolant hoses-1- and -2- remain connected.

- Remove harness connector (arrow) for oxygen sensor before catalytic converter from bracket.







- Disconnect harness connector and expose wire.
- Loosen upper bolt on connection of exhaust manifold/exhaust pipe.







- Loosen connecting bolts (arrows) at exhaust manifold/front exhaust pipe from below.







- Remove exhaust pipe from bracket (arrow).

NOTE: Decoupling element in front exhaust pipe must not be bent more than 10 degree, otherwise it may be damaged..






- Loosen double clamps -1- and -2- of exhaust system and slide them toward rear.
- Pull front exhaust pipe at left slightly toward rear.







- Remove heat shield for drive shaft -arrows-.







- Unbolt driveshaft -1- from transmission and let it rest on heat shield -2-.
- Secure driveshaft using wire (arrow) at bracket -3- of fuel lines.







- Position Engine-/Gearbox Jack V.A.G 1383 A -Item B- with stand -Item A- under transmission and support transmission.

NOTE: For vehicles with automatic transmission, support on transmission housing only and not on ATF pan of transmission.







- First remove bolts -1-, then bolts -2-.
- Slowly lower the rear subframe slightly using V.A.G 1383 A engine/transmission jack.
- Open all cable ties on transmission for wire connections of oxygen sensors behind catalytic converter.
- Expose cables.
- Carefully remove left exhaust pipe.

Installing
Installation is the reverse of removal, noting the following:

NOTE:
- Wires of oxygen sensors must always be secured in the same position when installing so that contact with the exhaust pipe is avoided.
- After removing driveshaft, always remove any remaining locking fluid from thread bores in the transmission drive flange. Otherwise there is a possibility that the new bolts may get jammed when installed and shear when removed
- Cleaning can be performed with a tap.
- Always replace driveshaft bolts (self-locking).

- Note the different tightening torques when securing the subframe.
- Use new bolts when securing.







- Tighten bolts -2- to 110 Nm + turn another 90 degree.
- Tighten bolts -1-. Note the different tightening methods for the various bolt versions, See the figure given below.

Bolt versions







Bolt -A- without ribbing.
Tightening torques: 25 Nm

Bolt -B- with ribbing.
Tightening torques: 75 Nm

Bolt -C- with screw head and washer ribbing.
Tightening torques: 30 Nm + turn another 90 degree.

- Align exhaust system free of stress.

Tightening torques

Component Nm
Driveshaft to transmission 55
Heat shield for driveshaft to cover for Torsen differential 25
Front exhaust pipe with catalytic converter to mounting strap 25
Front exhaust pipe with catalytic converter to exhaust manifold 25
Clamp for exhaust pipe 40