2.0L - Exhaust System, Emission Controls - Engine Code(s): Bpy: Other Audi A3 8P facelift

EXHAUST MANIFOLD

Note. The exhaust manifold and the turbocharger are a single component.

Exhaust manifold, removing and installing, refer to TURBOCHARGER .

Scheme 61

1. Nut Replace 40 Nm Coat turbocharger stud bolts with hot bolt paste.
2. Front Exhaust Pipe with Catalytic Converters and Front Muffler With front exhaust pipe Protect from shocks and impact stress With flex joint Flex joint must not be bent more than 10° - otherwise it may be damaged Removing and installing, refer to «FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS AND FRONT MUFFLER»(ref-496085-S22387601692012082100000) Install exhaust system free of stress, refer to «EXHAUST SYSTEM, ALIGNING»(ref-496085-S35054066952012082100000)
3. Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and Heater for Oxygen Sensor 1 after Catalytic Converter -Z29- Tightening specification, 55 Nm Only use hot bolt paste to grease thread; do not let paste get onto slits of oxygen sensor body Removing and installing, refer to «Removal and Installation»(ref-496075-S21350944552012082100000)
4. Retaining Loop Replace if damaged
5. Nut 23 Nm
6. Retaining Loop Replace if damaged
7. Rear Muffler Original equipment as one unit with center muffler. For repairs, replace each separately. Separating point «CENTER AND REAR MUFFLERS, SEPARATING»(ref-496085-S25034742522012082100000) Install exhaust system free of stress, refer to «EXHAUST SYSTEM, ALIGNING»(ref-496085-S35054066952012082100000)
8. Suspended Mount Replace if damaged
9. Bolt 23 Nm
10. Rear Clamping Sleeve For individual replacement of center and rear mufflers Installed location see scheme 3Tighten bolts evenly
11. Center Muffler Original equipment as one unit with rear muffler. For repairs, replace each part separately. Separating point «CENTER AND REAR MUFFLERS, SEPARATING»(ref-496085-S25034742522012082100000) Install exhaust system free of stress, refer to «EXHAUST SYSTEM, ALIGNING»(ref-496085-S35054066952012082100000)
12. Retaining Loop Replace if damaged
13. Bolt 23 Nm
14. Front Clamping Sleeve Before tightening, ensure exhaust system is tension-free, refer to «EXHAUST SYSTEM, ALIGNING»(ref-496085-S35054066952012082100000) Installed location (Scheme 62)Tighten bolts evenly
15. Nut 23 Nm
16. Suspended Mount
17. Bolt 23 Nm
18. Suspended Mount
19. Support
20. Bolts 40 Nm
21. Gasket Replace
22. Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19- Tightening specification, 55 Nm Only use hot bolt paste to grease thread; do not let paste get onto slits of oxygen sensor body Removing and installing, refer to «Removal and Installation»(ref-496075-S21350944552012082100000)

Scheme 62

Install clamping sleeve so that the end of the bolt does not extend beyond the lower edge of the clamping sleeve.

1. Threaded connection points toward the right.

Install clamping sleeve so that the end of the bolt does not extend beyond the lower edge of the clamping sleeve.

1. Threaded connection points to the rear.

EXHAUST SYSTEM, ALIGNING

1. Align exhaust system when cold.

1. For the correct tightening specifications, refer to «EXHAUST SYSTEM OVERVIEW»(ref-496085-S07128011272012082100000) .

Loosen front double clamping bolts EXHAUST SYSTEM OVERVIEW .

Push exhaust system far enough forward so tension at the retaining loop at rear muffler is a = 5 to 11 mm.

Scheme 63

Install clamping sleeve so that the end of the bolt does not extend beyond the lower edge of the clamping sleeve.

1. Threaded connection points toward the right.

Tighten clamping sleeve threaded connections evenly.

Aligning Tailpipe

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

Scheme 64

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

1. Dimension b = at least 22 mm

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

EXHAUST SYSTEM, CHECKING FOR LEAKS

Start engine and run at idle speed.

Seal tailpipe with cloths or plug 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.

FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS AND FRONT MUFFLER

Special tools and workshop equipment required

1. Spring Type Clip Pliers VAS 5024 A

Removing

Remove the engine cover and air filter. Refer to Removal and Installation .

Disconnect the electrical connector -arrow- for heated oxygen sensor (HO2S) -G39- and oxygen sensor (O2S) heater -Z19- and free up the wiring.

Scheme 65

Remove the accessible nuts -arrows- for the front exhaust pipe/turbocharger from above.

Scheme 66

Remove the right vehicle underbody cover -arrows-.

Scheme 67

Disconnect electrical connector -arrow- for oxygen sensor (O2S) after three way catalytic converter (TWC) -G130- and heater for oxygen sensor (O2S) 1 after catalytic converter -Z29- and free up wiring.

Scheme 68

Remove the remaining nuts -arrows- for the front exhaust pipe/turbocharger from below.

Remove the supports for the front exhaust pipe with catalytic converter, by removing bolts -1 and 2-.

Note. Flex joints in front exhaust pipe must not be bent more than 10°, otherwise they may be damaged.

Disconnect the exhaust system at the clamping sleeve -arrows-.

Scheme 69

Remove crossmember for vehicle floor -arrows-.

Scheme 70

Remove bracket for exhaust system -arrows-.

Scheme 71

Remove front exhaust pipe with catalytic converters and front muffler.

Installing

Install in reverse order of removal. Note the following

1. For the correct tightening specifications, refer to «EXHAUST SYSTEM OVERVIEW»(ref-496085-S07128011272012082100000)

Note. Replace gaskets and self-locking nuts.

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

CENTER AND REAR MUFFLERS, 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

1. For the correct tightening specifications, refer to «EXHAUST SYSTEM OVERVIEW»(ref-496085-S07128011272012082100000)

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

Scheme 72

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

Install clamping sleeve so that bolt end does not project beyond lower edge of clamping sleeve -arrow-.

1. Threaded connection points to the rear.

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