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2.0l - Exhaust System, Emission Controls - Engine Code(s): Cbfa & Ccta Audi A3 8P рестайлинг 2

Exhaust 21 illustrations ~1370 words

EXHAUST MANIFOLD

The exhaust manifold and turbocharger are one component. Refer to TURBOCHARGER ASSEMBLY OVERVIEW .

EXHAUST SYSTEM OVERVIEW

Note. The exhaust manifold and turbocharger are one component. Refer to TURBOCHARGER ASSEMBLY OVERVIEW .

Scheme 59

Scheme 59: EXHAUST SYSTEM OVERVIEW
Scheme 59: EXHAUST SYSTEM OVERVIEW
  1. Bolt 23 Nm
  2. Suspended Mount Replace if damaged
  3. Seal Replace
  4. Nut Replace 40 Nm Coat turbocharger stud bolts with hot bolt paste.
  5. Front Exhaust Pipe with Catalytic Converters CAUTION: Danger of damaging the decoupling element. Decoupling element must not be bent more than 10°. Do not load decoupling element on cable. Do not damage wire mesh at decoupling element. Protect catalytic converter from shocks and impact stress Removing and installing, refer to «FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER»(/audi/a3/8p-2-2008-2013/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cbfa-ccta__front-exhaust-pipe-with-catalytic-converter) Install exhaust system free of stress, refer to «EXHAUST SYSTEM, ALIGNING»(/audi/a3/8p-2-2008-2013/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cbfa-ccta__exhaust-system-aligning)
  6. Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19- Threads of new oxygen sensors are coated with assembly paste When installing a used oxygen sensor, coat threads with hot bolt paste; hot bolt paste. Make sure the hot bolt paste does not get into the slits in the sensor body. Removing and installing, refer to «Removal and Installation»(/audi/a3/8p-2-2008-2013/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-cbfa-ccta)
  7. Front Clamping Sleeve Before tightening, align exhaust system tension-free, refer to «EXHAUST SYSTEM, ALIGNING»(/audi/a3/8p-2-2008-2013/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cbfa-ccta__exhaust-system-aligning) Installed location «Installed Position of Front Clamping Sleeve»(/audi/a3/8p-2-2008-2013/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cbfa-ccta) Tighten bolts evenly
  8. Nut 25 Nm
  9. Rear Clamping Sleeve Before tightening, align exhaust system tension-free, refer to «EXHAUST SYSTEM, ALIGNING»(/audi/a3/8p-2-2008-2013/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cbfa-ccta__exhaust-system-aligning) Installed location «Installed Position of Rear Clamping Sleeve»(/audi/a3/8p-2-2008-2013/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cbfa-ccta) Tighten bolts evenly
  10. Nut 25 Nm
  11. Retaining Loop Replace if damaged
  12. Rear Muffler Original equipment as one unit with rear muffler. For repairs, replace each separately. Separating point, Separate exhaust pipe at a right angle at the separating point -arrow 2- using a chain pipe cutter VAS 6254. Refer to «CENTER MUFFLER AND REAR MUFFLER, SEPARATING»(/audi/a3/8p-2-2008-2013/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cbfa-ccta__center-muffler-and-rear-muffler-separating) Install exhaust system free of stress, refer to «EXHAUST SYSTEM, ALIGNING»(/audi/a3/8p-2-2008-2013/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cbfa-ccta__exhaust-system-aligning)
  13. Suspended Mount Replace if damaged
  14. Bolt 23 Nm
  15. Bolt 23 Nm
  16. Retaining Loop Replace if damaged
  17. Bracket for Exhaust System
  18. Center Muffler Original equipment as one unit with rear muffler. For repairs, replace each separately. Separating point. Separate exhaust pipe at a right angle at the separating point -arrow 2- using a chain pipe cutter VAS 6254. Refer to «CENTER MUFFLER AND REAR MUFFLER, SEPARATING»(/audi/a3/8p-2-2008-2013/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cbfa-ccta__center-muffler-and-rear-muffler-separating) Install exhaust system free of stress, refer to «EXHAUST SYSTEM, ALIGNING»(/audi/a3/8p-2-2008-2013/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cbfa-ccta__exhaust-system-aligning)

Scheme 60

Scheme 60: Installed Position of Front Clamping Sleeve
Scheme 60: Installed Position of Front Clamping Sleeve

Install clamping sleeve in angle position shown.

  1. Threaded connections point toward the right.
  2. Nuts face up.
  3. α = approximately 20°

Scheme 61

Scheme 61: Installed Position of Rear Clamping Sleeve
Scheme 61: Installed Position of Rear Clamping Sleeve

Install the clamping sleeve so that the ends of the bolt do not extend beyond the lower edge of the clamping sleeve.

  1. The threaded connections face downward.

Scheme 62

Scheme 62: SECONDARY AIR INJECTION SYSTEM ASSEMBLY OVERVIEW
Scheme 62: SECONDARY AIR INJECTION SYSTEM ASSEMBLY OVERVIEW
  1. Seal Replace
  2. Secondary Air Injection (AIR) Solenoid Valve -N112- Removing and installing, refer to «SECONDARY AIR INJECTION SOLENOID VALVE»(/audi/a3/8p-2-2008-2013/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cbfa-ccta__secondary-air-injection-solenoid-valve)
  3. Bolt 9 Nm
  4. Secondary Air Injection Sensor 1 -G609
  5. Seal Replace
  6. To Air Filter
  7. Secondary Air Lines
  8. Routing Aid for the Air Filter Drain Line
  9. Nut 9 Nm
  10. Bracket for the Secondary Air Injection (AIR) Pump Motor -V101
  11. Nut 25 Nm
  12. Secondary Air Injection (AIR) Pump Motor -V101- Removing and installing, refer to «SECONDARY AIR INJECTION PUMP MOTOR»(/audi/a3/8p-2-2008-2013/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cbfa-ccta__secondary-air-injection-pump-motor-v101)

FASTENER TIGHTENING SPECIFICATIONS

ComponentBolt SizeNm
Bracket for Exhaust System23
Bracket For The Secondary Air Injection Pump Motor To Secondary Air Injection Pump Motor. 2)
Nut9
Nut25
Front Clamping Sleeve, Nut25
Front Exhaust Pipe with Catalytic Converters, Nut. 1), 3)40
Rear Clamping Sleeve25
Secondary Air Injection (AIR) Solenoid Valve9
Suspended Mount23
1) Always replace 2) For bolt tightening clarification, refer to SECONDARY AIR INJECTION SYSTEM ASSEMBLY OVERVIEW and see items -9 and 11- 3) Coat turbocharger stud bolts with hot bolt paste.

EXHAUST SYSTEM, CHECKING FOR LEAKS

Start engine and let run at idle.

Seal off the tail pipes with cloths or plug them for the duration of the leak test.

Check for leaks by listening at connection areas of cylinder head/exhaust manifold, exhaust manifold/front exhaust pipe etc.

Repair detected leaks.

CENTER MUFFLER AND REAR MUFFLER, SEPARATING

  1. A separating point has been provided in the connecting pipe for individual replacement of the center or rear muffler.
  2. The separating point is marked by depressions around the circumference of the exhaust pipe.

Special tools and workshop equipment required

  1. Chain Pipe Cutter VAS 6254

Procedure

Separate exhaust pipe at a right angle at the separating point -arrow 2- using a chain pipe cutter VAS 6254.

Scheme 63

Scheme 63
Scheme 63

Position the clamping sleeve -4- at the side markings -arrow 1- and -arrow 3- when installing.

Install the clamping sleeve so that the ends of the bolt do not extend beyond the lower edge of the clamping sleeve.

  1. The threaded connections face downward.

Install exhaust system free of stress. Refer to EXHAUST SYSTEM, ALIGNING .

FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER

Removing

Remove the cover for the air guide; to do so disengage the side clips -arrows-.

Scheme 64

Scheme 64: FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER
Scheme 64: FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER

Unclip the lower air guide, to do so disengage the clips -arrows-.

Scheme 65

Scheme 65
Scheme 65

Remove the lower air guide together with the air guide hose.

Disconnect electrical connector -1- on mass air flow (MAF) sensor -G70-.

Scheme 66

Scheme 66
Scheme 66

Remove the air guide hose -2-.

Remove the bolt -4- and the air filter housing.

Note. Ignore -3-.

From above, remove the nuts -arrows- on the front exhaust pipe connection to the turbocharger.

Scheme 67

Scheme 67
Scheme 67

All Wheel Drive (AWD)

Mark position of flexible disc to bevel box flange for reinstallation.

Scheme 68

Scheme 68
Scheme 68

Remove the driveshaft flexible disc bolts -arrows- from the bevel box while counter holding at the triangular flange with a lever.

Scheme 69

Scheme 69
Scheme 69
CAUTIONThe shaft seal -arrow- in the driveshaft flange could be damaged. Press driveshaft horizontally as far back and to right side of vehicle as possible.

All Vehicles

Remove nuts accessible from below from front exhaust pipe to the turbocharger connection.

Disconnect the connector on the heated oxygen sensor (HO2S) --. Refer to Removal and Installation .

Remove exhaust system bracket -arrows-.

Scheme 70

Scheme 70
Scheme 70

Remove the front cross member for the vehicle floor -arrows-.

Scheme 71

Scheme 71
Scheme 71
CAUTIONRisk of damaging decoupling elements. Do not bend decoupling element in front exhaust pipe more than 10°.

Loosen clamping sleeve -1- and push it rearward.

Remove the catalytic converter with the front exhaust pipe.

Installing

  1. Tightening specifications, refer to «MUFFLER ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cbfa-ccta__exhaust-system-overview) .

Installation is in reverse order of removal, note the following

Note. Replace gaskets and self-locking nuts.

Install exhaust system free of stress. Refer to EXHAUST SYSTEM, ALIGNING .

EXHAUST SYSTEM, ALIGNING

  1. Align exhaust system when cold.
  2. Tightening specifications, refer to «MUFFLER ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cbfa-ccta__exhaust-system-overview) .

Loosen the bolts on the front clamping sleeve ) Front Clamping Sleeve .

Push the exhaust system far enough forward -arrow- so that the tension at the retaining loop at the rear muffler is -a- = 15 to 17 mm.

Scheme 72

Scheme 72
Scheme 72

Position the clamping sleeve in the angle shown.

  1. Threaded connections point toward the right.
  2. Nuts face up.
  3. α = approximately 20°

Tighten the clamping sleeve threaded connections evenly.

Align the tail pipes

Align the tail pipes so the distance -a- is the same on the left and right.

Scheme 73

Scheme 73
Scheme 73

At the same time, the clearance -b- from the bumper cut-out to the tail pipes must be achieved.

  1. Dimension b = minimum 21 mm

If necessary, loosen the suspended mountings of the rear muffler to align the tail pipes.

SECONDARY AIR INJECTION PUMP MOTOR -V101

Removing

Remove noise insulation. Refer to Removal and Installation .

Remove the left front wheel housing liner. Refer to FRONT WHEEL HOUSING LINER .

Cabriolet

Remove the noise insulation bracket. Refer to Removal and Installation .

All Vehicles

Loosen the lines -1-, loosen the bolts -2-, disconnect the electrical connector -3- and remove the secondary air injection (AIR) pump motor -V101-.

Scheme 74

Scheme 74: SECONDARY AIR INJECTION PUMP MOTOR -V101
Scheme 74: SECONDARY AIR INJECTION PUMP MOTOR -V101

Installing

Installation is in reverse order of removal.

SECONDARY AIR INJECTION SOLENOID VALVE

Removing

Remove the air filter. Refer to Removal and Installation .

CAUTIONRisk of destroying electrical components when battery is disconnected. Complete the steps for disconnecting the battery.

Remove the battery. Refer to Removal and Installation .

Remove the battery tray -arrows-.

Scheme 75

Scheme 75
Scheme 75

Disconnect the connector -A- and hose -B- from the secondary air injection (AIR) solenoid valve -N112-.

Scheme 76

Scheme 76
Scheme 76

Loosen the coolant pipe; remove the bolts -arrows-.

Scheme 77

Scheme 77
Scheme 77

Remove the bolts -arrows- and remove the secondary air injection (AIR) solenoid valve -N112-.

Scheme 78

Scheme 78
Scheme 78

Installing

  1. Tightening specifications, refer to «CYLINDER HEAD ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-cbfa-ccta__cylinder-head-assembly-overview) .

Installation is in reverse order of removal, note the following

Note. Replace gaskets and self-locking nuts.

Install the battery. Refer to Removal and Installation .

Install the air filter. Refer to Removal and Installation .

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 79

Scheme 79: SPECIAL TOOLS
Scheme 79: SPECIAL TOOLS
  1. Chain Pipe Cutter VAS 6254

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