Removal and installation of the exhaust system (Audi A3 Type 8L)

System of release of the fulfilled gases. Engine without turbocharger

On the 1.8L turbocharged engine, there are differences in the exhaust pipe flange of the muffler.

• 1 crossbar. With a hole for installing the exhaust system.
• 2 suspension
• 3 bolt, 25 Nm
• 4 downpipe, catalytic converter
• Do not drop, protect from shocks and shocks.
• 5 nut, 40 Nm. Self-stopping, be sure to install a new one.
• 6 seal. Be sure to replace.
• 7 exhaust manifold
• 8 nut, 25 Nm
• 9 oxygen sensor, 50 Nm
• 10 clamp

Working position: the bolted connection is located horizontally on the left side of the car.

• 11 nut, 40 Nm
• 12 suspension
• 13 bolt, 25 Nm
• 14 additional and main mufflers. During repair, they are disconnected and replaced separately.
• 15 Nut, 25 Nm

System of release of the fulfilled gases. diesel engine

• 1 bolt, 20 Nm
• 2 tunnel bridge. With a hole for installing the exhaust system.
• 3 suspension
• 4 bolt, 25 Nm
• 5 bolt, 25 Nm
• 6 pendant
• 7 bolt, 25 Nm
• 8 nut, 25 Nm. Self-locking, must be replaced.
• 9 seal. Be sure to replace.
• 10 downpipe, catalytic converter. Do not drop, protect from shocks and shocks.
• 11 collar. Working position: the bolted connection is located horizontally on the left side of the car.
• 12 nut, 40 Nm
• 13 suspension
• 14 suspension
• 15 bolt, 25 Nm
• 16 suspension
• 17 main muffler

Withdrawal

Warning: Elements of the exhaust system can be removed separately. The central and additional mufflers can be separated from each other. They exist as separate spare parts, refer to subsection Replacing the central / additional muffler.

Warning: There is danger when lifting and placing the vehicle on stands! Therefore, first read the subsection car jacking.

1. Raise and place the car on stands.

2. Spray all bolts and nuts of the exhaust system with a rust-dissolving agent. Wait a while.



3. Unscrew the cover of the plug connection of the oxygen sensor next to the catalytic converter (arrow at the bottom of the illustration). Disconnect the electrical wire with clips (top arrow) at the heat shield. Remove the connector from the cover and unplug it.



4. Turn away the lower bolts of fastening of a reception pipe at an exhaust manifold or a turbocharger.

5. Place supports under the exhaust system or hang it on a wire from the bottom of the car so that it does not fall.

Warning: Never drop the exhaust system as this may damage the catalytic converter ceramics. This will result in the need to replace the catalytic converter.

6. Turn away from both parties bolts of fastening of a forward cross member of system of release to the bottom.

7. With the help of an assistant, remove the exhaust system from the mounts.

Installation

Warning: Be sure to replace seals, nuts and bolts with new ones. To facilitate subsequent disassembly, it is recommended that the nuts and bolts of the exhaust system be coated with high-temperature paste, for example, Liqui Moly LM-508-ASC, before reinstallation.

8. If the mufflers are not replaced, the sealing and contact surfaces must be cleaned with sandpaper to remove rust and sealant residues before assembly.

Warning: The turbocharger has flexible (disconnecting) do not bend the element in the downpipe by more than 10°, otherwise it may be damaged.

9. Bolt the exhaust holders at the front cross member so that the bent side of the holder (arrow illustration) looking in the direction of travel.

10. Install the exhaust system with the help of an assistant and hang it from behind in the rubber holders.


11. Fasten the front cross member with bolts to the moment of 25 N·m to the bottom of the car.



12. Engines without turbocharger: Bolt the exhaust pipe with a new gasket to the exhaust manifold and tighten in the sequence shown in the illustration crosswise to a torque of 40 Nm.

13. Engines with turbocharger: Fasten the downpipe with a new gasket to the turbocharger crosswise with a torque of 40 Nm for petrol and 25 Nm for diesel engines.

14. Align the exhaust system so that it lies in the suspensions without interference.

15. Tighten bolts and nuts of fastening by the efforts specified in Specifications.

16. Establish the bottom cover of an impellent compartment, thus address to subsection Removal and installation of the bottom cover of an impellent compartment.

17. Place the oxygen sensor cable in the clamps and connect. Screw the cover of the plug connection onto the bottom.

18. Lower the car onto its wheels.

19. Check the exhaust system for leaks, while referring to the relevant subsection Check of a condition of system of release of the fulfilled gases.