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Exhaust System, Emission Controls (3.0l Avk) Audi A4 B6

Exhaust 26 illustrations ~8815 words

Exhaust system, servicing

Note. Always replace gaskets and self-locking nuts. After exhaust system repairs, make sure exhaust system is not under stress and is far enough from the body. If necessary, loosen clamps and align mufflers and exhaust pipes so that there is adequate distance to vehicle body, and weight is evenly distributed among the exhaust hangers. Flex joint in front exhaust pipe must not be bent more than 10°, otherwise it may be damaged.

Exhaust system components, overview (Front Wheel Drive vehicles)

The following list pertains to (Scheme 1).

  1. Center muffler Factory installed with rear muffler as one unit. If repair is necessary, replace separately Cutting point, see «Procedure»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__procedure) Install exhaust system free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress)
  2. 23 Nm
  3. Support ring Replace if damaged
  4. 27 Nm Always replace
  5. Exhaust manifold For cylinder bank 1 (right) Removing and installing. See «RIGHT EXHAUST MANIFOLD, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk)
  6. Gasket Always replace
  7. Oxygen sensor - 55 Nm Before catalytic converter For cylinder bank 1 (right) Only grease threads with "G 052 112 A3", do NOT allow grease to get into slots on sensor body
  8. Oxygen sensor - 55 Nm Before catalytic converter For cylinder bank 2 (left) Only grease threads with "G 052 112 A3", do NOT allow grease to get into slots on sensor body
  9. Exhaust manifold For cylinder bank 2 (left) Removing and installing. See «LEFT EXHAUST MANIFOLD, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk)
  10. Gasket Always replace
  11. 27 Nm Always replace
  12. Oxygen sensor - 55 Nm Behind catalytic converter For cylinder bank 2 (left) Only grease threads with "G 052 112 A3", do NOT allow grease to get into slots on sensor body
  13. Front exhaust pipe with catalytic converter For cylinder bank 2 (left) With decoupling element Decoupling element must not be bent more than 10°, otherwise it may be damaged Protect from hit- and impact stress Install exhaust system free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) . Individual mounting components for vehicles with manual transmission. See «INDIVIDUAL LEFT MOUNTING COMPONENTS FOR VEHICLES WITH MANUAL TRANSMISSION»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__individual-left-mounting-components-for-vehicles) . Individual mounting components for vehicles with automatic transmission 01J. See «INDIVIDUAL LEFT MOUNTING COMPONENTS FOR VEHICLES WITH AUTOMATIC TRANSMISSION 01J»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__individual-left-mounting-components-for-vehicles) . Vehicles with manual transmission, removing and installing. See «LEFT FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER, REMOVING AND INSTALLING (VEHICLES WITH MANUAL TRANSMISSION)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) . Vehicles with automatic transmission 01 J, removing and installing. See «LEFT FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER, REMOVING AND INSTALLING (VEHICLES WITH AUTOMATIC TRANSMISSION 01J)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) .
  14. Front clamping sleeve Before tightening ensure exhaust system is free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) . Installation position. See «INSTALLED POSITION OF FRONT CLAMPING SLEEVES»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__installed-position-of-front-clamping-sleeves) . Tighten bolts evenly
  15. 40 Nm
  16. Oxygen sensor - 55 Nm Behind catalytic converter For cylinder bank 1 (right) Only grease threads with "G 052 112 A3", do NOT allow grease to get into slots on sensor body
  17. Front exhaust pipe with catalytic converter For cylinder bank 1 (right) With decoupling element Decoupling element must not be bent more than 10°, otherwise it may be damaged Protect from hit- and impact stress Install exhaust system free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) . Individual mounting components for vehicles with manual transmission. See «INDIVIDUAL RIGHT MOUNTING COMPONENTS FOR VEHICLES WITH MANUAL TRANSMISSION»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__individual-right-mounting-components-for-vehicles) . Individual mounting components for vehicles with automatic transmission 01J. See «INDIVIDUAL RIGHT MOUNTING COMPONENTS FOR VEHICLES WITH AUTOMATIC TRANSMISSION 01J»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__individual-right-mounting-components-for-vehicles) Vehicles with manual transmission, removing and installing. See «RIGHT FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER, REMOVING AND INSTALLING (VEHICLES WITH MANUAL TRANSMISSION)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) Vehicles with automatic transmission 01 J, removing and installing. See «RIGHT FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER, REMOVING AND INSTALLING (VEHICLES WITH AUTOMATIC TRANSMISSION 01J)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) .
  18. Rear muffler For left side of vehicle Factory-installed with center muffler as one unit. If repair is necessary, replace separately Cutting point, see «PROCEDURE»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__procedure) Replacing end pipes, see «REPLACING END PIPE»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__replacing-end-pipe) Install exhaust system free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) .
  19. Support ring Replace if damaged
  20. 23 Nm
  21. Rear muffler For right side of vehicle Factory-installed with center muffler as one unit. If repair is necessary, replace separately Cutting point, see «PROCEDURE»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__procedure) Replacing end pipes, see «REPLACING END PIPE»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__replacing-end-pipe) Install exhaust system free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) .
  22. 23 Nm
  23. Rear clamping sleeve Used when center or rear muffler is replaced separately. Before tightening ensure exhaust system is free of stress, see «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) . Installation position, see «INSTALLED POSITION OF REAR CLAMPING SLEEVES»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__installed-position-of-rear-clamping-sleeves) Tighten bolts evenly
  24. 40 Nm
  25. Support ring Replace if damaged
  26. 23 Nm

Exhaust system components, overview, (All Wheel Drive vehicles)

The following list pertains to (Scheme 2).

  1. 23 Nm
  2. Support ring Replace if damaged
  3. Center muffler Factory-installed with rear muffler as one unit. If repair is necessary, replace separately Cutting point, see «PROCEDURE»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__procedure) Install exhaust system free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress)
  4. 27 Nm Always replace
  5. Exhaust manifold For cylinder bank 1 (right) Removing and installing, see «RIGHT EXHAUST MANIFOLD, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk)
  6. Gasket Always replace
  7. Oxygen sensor - 55 Nm Before catalytic converter For cylinder bank 1 (right) Only grease threads with "G 052 112 A3", do NOT allow grease to get into slots on sensor body
  8. Oxygen sensor - 55 Nm Before catalytic converter For cylinder bank 2 (left) Only grease threads with "G 052 112 A3", do NOT allow grease to get into slots on sensor body
  9. Exhaust manifold Cylinder bank 2 (left) Removing and installing, see «LEFT EXHAUST MANIFOLD, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk)
  10. Gasket Always replace
  11. 27 Nm Always replace
  12. Oxygen sensor - 55 Nm Behind catalytic converter For cylinder bank 2 (left) Only grease threads with "G 052 112 A3", do NOT allow grease to get into slots on sensor body
  13. Front exhaust pipe with catalytic converter For cylinder bank 2 (left) With decoupling element Decoupling element must not be bent more than 10°, otherwise it may be damaged Protect from hit- and impact stress Install exhaust system free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) . Individual mounting components for vehicles with manual transmission, see «INDIVIDUAL RIGHT MOUNTING COMPONENTS FOR VEHICLES WITH MANUAL TRANSMISSION»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__individual-right-mounting-components-for-vehicles) Individual mounting components for vehicles with automatic transmission 01V, see «INDIVIDUAL RIGHT MOUNTING COMPONENTS FOR VEHICLES WITH AUTOMATIC TRANSMISSION 01V»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__individual-right-mounting-components-for-vehicles) Vehicles with manual transmission, removing and installing, see «RIGHT FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER, REMOVING AND INSTALLING (VEHICLES WITH MANUAL TRANSMISSION)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) Vehicles with automatic transmission 01V, removing and installing, see «RIGHT FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER, REMOVING AND INSTALLING (VEHICLES WITH AUTOMATIC TRANSMISSION 01V)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk)
  14. Front clamping sleeve Before tightening ensure exhaust system is free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) . Installation position, see «INSTALLED POSITION OF FRONT CLAMPING SLEEVES»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__installed-position-of-front-clamping-sleeves) Tighten bolts evenly
  15. 40 Nm
  16. Oxygen sensor - 55 Nm Behind catalytic converter For cylinder bank 1 (right) Only grease threads with "G 052 112 A3", do NOT allow grease to get into slots on sensor body
  17. Front exhaust pipe with catalytic converter For cylinder bank 1 (right) With decoupling element Decoupling element must not be bent more than 10°, otherwise it may be damaged Protect from hit- and impact stress Install exhaust system free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) . Individual mounting components for vehicles with manual transmission, see «INDIVIDUAL LEFT MOUNTING COMPONENTS FOR VEHICLES WITH MANUAL TRANSMISSION»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__individual-left-mounting-components-for-vehicles) Individual mounting components for vehicles with automatic transmission 01V, see «INDIVIDUAL LEFT MOUNTING COMPONENTS FOR VEHICLES WITH AUTOMATIC TRANSMISSION 01V»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__individual-left-mounting-components-for-vehicles) Vehicles with manual transmission, removing and installing, see «LEFT FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER, REMOVING AND INSTALLING (VEHICLES WITH MANUAL TRANSMISSION)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) Vehicles with automatic transmission 01V, removing and installing, see «LEFT FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER, REMOVING AND INSTALLING (VEHICLES WITH AUTOMATIC TRANSMISSION 01V)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk)
  18. Rear muffler For left side of vehicle Factory-installed with center muffler as one unit. If repair is necessary, replace separately Cutting point, see «PROCEDURE»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__procedure) Replacing end pipes, see «REPLACING END PIPE»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__replacing-end-pipe) Install exhaust system free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) .
  19. Support ring Replace if damaged
  20. 23 Nm
  21. Rear muffler For right side of vehicle Factory-installed with center muffler as one unit. If repair is necessary, replace separately Cutting point, see «PROCEDURE»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__procedure) Replacing end pipes, see «REPLACING END PIPE»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__replacing-end-pipe) Install exhaust system free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) .
  22. 23 Nm
  23. 40 Nm
  24. Rear clamping sleeve Used when center or rear muffler is replaced separately. Before tightening ensure exhaust system is free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) . Installation position, see «INSTALLED POSITION OF REAR CLAMPING SLEEVES»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__installed-position-of-rear-clamping-sleeves) Tighten bolts evenly

Installed position of front clamping sleeves

  1. Install double clamps so that the bolt ends do not project over lower edge of double clamp. Threaded connections face each other

Scheme 1

Scheme 1
Scheme 1

Installed position of rear clamping sleeves

  1. Install double clamps so that the bolt ends do not project over lower edge of double clamp. Threaded connections face outward

Individual left mounting components for vehicles with manual transmission

  1. Self-locking nut (25Nm)
  2. Spacer sleeve
  3. Strap
  4. Buffer
  5. Spacer sleeve
  6. Bolt (25Nm)
  7. Washer
  8. Compression spring
  9. Spacer sleeve

Individual right mounting components for vehicles with manual transmission

Note. The following list refers to items in (Scheme 6).

  1. Spacer sleeve
  2. Strap
  3. Compression spring
  4. Washer
  5. Bolt (25 Nm)
  6. Spacer sleeve
  7. Buffer
  8. Spacer sleeve
  9. Self-locking nut (25 Nm)

Individual left mounting components for vehicles with automatic transmission 01V

Note. The following list refers to items in (Scheme 7).

  1. Bolt (25 Nm)
  2. Heat shield for selector lever cable
  3. Spacer sleeve
  4. Buffer
  5. Strap
  6. Spacer sleeve
  7. Pivot
  8. Self-locking nut (25 Nm)
  9. Compression spring
  10. Spacer sleeve
  11. Washer

Individual right mounting components for vehicles with automatic transmission 01V

Note. The following list refers to items in (Scheme 8).

  1. Washer
  2. Bolt (25 Nm)
  3. Spacer sleeve
  4. Buffer
  5. Strap
  6. Spacer sleeve
  7. Self-locking nut (25 Nm)
  8. Compression spring
  9. Spacer sleeve

Individual left mounting components for vehicles with automatic transmission 01J

Note. The following list refers to items in (Scheme 9).

  1. Bolt (25 Nm)
  2. Washer
  3. Compression spring
  4. Spacer sleeve
  5. Self-locking nut (25 Nm)
  6. Bolt (25 Nm)
  7. Spacer sleeve
  8. Buffer
  9. Strap
  10. Spacer sleeve

Individual right mounting components for vehicles with automatic transmission 01J

Note. The following list refers to items in (Scheme 10).

  1. Self-locking nut (25 Nm)
  2. Bolt (25 Nm)
  3. Spacer sleeve
  4. Buffer
  5. Strap
  6. Spacer sleeve
  7. Bolt (25 Nm)
  8. Washer
  9. Compression spring
  10. Spacer sleeve

Replacing end pipe

WARNINGWear protective glasses.
  1. Using VAG1523 saw, cut end pipe - 1 - at cutting point -C- at right angle.
  2. Connect end pipe -3- up to marking -A-, so that the slot on end pipe lines up with marking -B- on cover.
  3. Tighten mounting bolt of clamp -2- to 25 Nm.

Center 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. Separating point is marked by a depression around the circumference of the exhaust pipe.

Special tools and equipment

  1. VAG1523A body repair saw
  2. Protective glasses

Note. An All Wheel Drive (AWD) vehicle is shown in the illustrations. For vehicles with Front Wheel Drive (FWD), the work steps are the same as for vehicles with All Wheel Drive (AWD).

Procedure

WARNINGWear protective glasses.

Scheme 2

Scheme 2
Scheme 2

Scheme 3

Scheme 3
Scheme 3
  1. Using VAG1523 A saw, cut exhaust pipes at separating point (arrow) at a right angle. NOTE: Separating point is the middle one of the 3 depressions on the exhaust pipe.
  2. When installing, center double clamps -1- and -2- on separation cut. Installation position of double clamps, see «INSTALLED POSITION OF REAR CLAMPING SLEEVES»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__installed-position-of-rear-clamping-sleeves)
  3. Install exhaust system free of stress, se «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) and «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) .
  4. Align rear muffler horizontally.
  5. Tighten double clamp bolts uniformly to 40 Nm.

Scheme 4

Scheme 4: Removing
Scheme 4: Removing

Scheme 5

Scheme 5
Scheme 5
  1. Remove rear engine cover (arrows).
  2. Remove cover -1- in engine compartment (left side).
  3. Remove coolant reservoir (arrow)
  4. Disconnect electrical wiring to Engine Coolant Level (ECL) Warning Switch -F66- at bottom of coolant reservoir.
  5. Tie coolant reservoir with connected coolant hoses -1 to 3- to side.
  6. Remove heat shield for harness connectors at left of bulkhead, if installed.
  7. Remove harness connectors -1 to 4- from bracket at left of bulkhead.
  8. Disconnect electrical harness connectors -1- and -4-.
  9. Guide wires to the oxygen sensors downward.
  10. Remove nut -2- for exhaust pipe/exhaust manifold which is accessible from top. NOTE: Illustration is shown with engine removed.
  11. Remove left front wheel.
  12. For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater on noise insulation.
  13. Remove bolts or release quick-release screws -1- and -2- and remove front noise insulation.
  14. Release quick-release screws -3- and remove rear noise insulation, if present.
  15. Remove bolts -1- through -4- and remove crossmember. NOTE: Flex joint in front exhaust pipe must not be bent more than 10°, otherwise it may be damaged.
  16. Disconnect exhaust system at left double clamp (left arrow).
  17. Remove heat shield -1- for left drive axle.
  18. Remove bracket for front exhaust pipe (arrow).
  19. Expose oxygen sensor wires.
  20. Remove nuts -1- and -3- for front exhaust pipe/exhaust manifold which are accessible from bottom. NOTE: Illustration is shown with engine removed.
  21. Remove front exhaust pipe with catalytic converter.

Installing

Installation is reverse of removal, noting the following

Note. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation. Oxygen sensor wiring must always be secured in the same position when installing so that contact with the exhaust pipe is avoided. Replace gaskets and self-locking nuts.

  1. Install exhaust system free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) and «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) . NOTE: For individual mounting components for exhaust system to transmission on vehicles with manual transmission, see «INDIVIDUAL LEFT MOUNTING COMPONENTS FOR VEHICLES WITH MANUAL TRANSMISSION»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__individual-left-mounting-components-for-vehicles) .

Tightening torques

ComponentNm
Front exhaust pipe with catalytic converter to exhaust manifold27
Front exhaust pipe with catalytic converter to hanging strap25
Drive axle protection to transmission23

TIGHTENING TORQUES: LH EXHAUST SYSTEM (M\T)

Scheme 6

Scheme 6: Removing
Scheme 6: Removing
  1. Remove rear engine cover (arrows).
  2. Remove cover -1- in engine compartment (right side).
  3. Remove bolts (arrows).
  4. Detach Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- -1- at air guide.
  5. Remove air guide -2-.
  6. Remove air filter housing (arrows).
  7. Remove bolts for holding plate -3- for solenoid valves (arrows).
  8. Disconnect electrical harness connector at Mass Air Flow (MAF) sensor.
  9. Remove hose -4- from air duct -2-.
  10. Remove bolt (arrow) and disconnect air duct -2- at throttle valve control module.
  11. Disconnect hose -1- from air duct. NOTE: Illustration shows the air guide from rear with the engine removed.
  12. Remove harness connectors -1 to 4- from bracket at right of bulkhead.
  13. Disconnect electrical harness connectors -1- and -4-.
  14. Guide wires to the oxygen sensors downward.
  15. Remove nut -2- for exhaust pipe/exhaust manifold which is accessible from top. NOTE: Illustration is shown with engine removed.
  16. Remove right front wheel
  17. For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater on noise insulation.
  18. Remove bolts or release quick-release screws -1- and -2- and remove front noise insulation.
  19. Remove quick-release screws -3- and remove rear noise insulation, if present.
  20. Remove bolts -1- through -4- and remove crossmember. NOTE: Flex joint in front exhaust pipe must not be bent more than 10°, otherwise it may be damaged..
  21. Disconnect exhaust system at right double clamp (right arrow).
  22. Remove heat shield -1- for right drive axle.
  23. Remove bracket for front exhaust pipe (arrow).
  24. Expose oxygen sensor wires.
  25. Remove nuts -1- and -3- for front exhaust pipe/exhaust manifold which are accessible from bottom. NOTE: Illustration is shown with engine removed.
  26. Remove front exhaust pipe with catalytic converter.

Installation is reverse of removal, noting the following

Note. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation. Oxygen sensor wiring must always be secured in the same position when installing so that contact with the exhaust pipe is avoided. Replace gaskets and self-locking nuts.

  1. Install exhaust system free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) and «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) . NOTE: For individual mounting components for exhaust system to transmission on vehicles with manual transmission, see «INDIVIDUAL RIGHT MOUNTING COMPONENTS FOR VEHICLES WITH MANUAL TRANSMISSION»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__individual-right-mounting-components-for-vehicles) .
ComponentNm
Front exhaust pipe with catalytic converter to exhaust manifold27
Front exhaust pipe with catalytic converter to hanging strap25
Drive axle protection to transmission23

TIGHTENING TORQUES: RH EXHAUST SYSTEM (M\T)

  1. 3337 wrench, 7-piece set
  2. Engine/transmission hoist
  3. Locking compound G 052 112 A3

Removing

  1. Remove rear engine cover (arrows).
  2. Remove cover -1- in engine compartment (right side).
  3. Remove bolts for holding plate -3- for solenoid valves (arrows).
  4. Disconnect intake air hose -1- at Mass Air Flow (MAF) sensor.
  5. Remove hose -4- from air duct -2-.
  6. Remove bolt (arrow) and disconnect air duct -2- at throttle valve control module.
  7. Disconnect hose -1- from air duct. NOTE: Illustration shows the air guide from rear with the engine removed.
  8. Remove cover -1- in engine compartment (left side).
  9. Remove coolant reservoir (arrow)
  10. Disconnect electrical wiring to Engine Coolant Level (ECL) Warning Switch -F66- at bottom of coolant reservoir.
  11. Tie coolant reservoir with connected coolant hoses -1 to 3- to side.
  12. Disconnect vacuum hose to brake booster (arrows).
  13. Remove heat shield for harness connectors at left of bulkhead, if installed.
  14. Remove harness connectors -1 to 4- from bracket at left of bulkhead.
  15. Disconnect electrical harness connectors -1- and -4-.
  16. Move wires to oxygen sensors clear.
  17. Unscrew oxygen sensor behind catalytic converter (arrow) using special tool 3337/7. NOTE: Illustration is shown with engine removed.
  18. Remove nut -2- for exhaust pipe/exhaust manifold which is accessible from top. NOTE: Illustration is shown with engine removed.
  19. Remove left front wheel.
  20. For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater on noise insulation.
  21. Remove bolts or release quick-release screws -1- and -2- and remove front noise insulation.
  22. Remove quick-release screws -3- and remove rear noise insulation, if present.
  23. Remove bolts -1- through -4- and remove crossmember. NOTE: Flex joint in front exhaust pipe must not be bent more than 10°, otherwise it may be damaged..
  24. Disconnect exhaust system at both double clamps -arrows-.
  25. Remove VAG1359/2 universal mount from VAG1383A engine/gearbox jack and insert a piece of wood -1- instead.
  26. Support rear cross member using VAG1383A engine/transmission jack.
  27. First remove bolts -1- and -2-, then bolts -3- and -4-.
  28. Release slowly the rear cross member using VAG1383A engine/transmission jack.
  29. Set aside VAG1383A engine/transmission jack.
  30. Remove nuts (arrows) and rear cross member.
  31. Remove heat shield -1- for left drive axle.
  32. Remove bracket for front exhaust pipe (arrows).
  33. Expose oxygen sensor wire.
  34. Remove nuts -1- and -3- for front exhaust pipe/exhaust manifold which are accessible from bottom. NOTE: Illustration is shown with engine removed.
  35. Loosen lower nuts -1- several turns on left and right of engine mount.
  36. Press transmission to the right.
  37. Remove front exhaust pipe with catalytic converter.

Installation is reverse of removal, noting the following

Note. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation. Oxygen sensor threads are coated with an assembly paste. This paste must not contact sensor openings. Oxygen sensor wiring must always be secured in the same position when installing so that contact with the exhaust pipe is avoided. Replace gaskets and self-locking nuts.

  1. Install subframe: See «SUBFRAME & BUSHINGS»(/audi/a4/b6-2000-2006/remont/suspension-front/#suspension-front)
  2. Install engine free of stress.
  3. Install exhaust system free of stress, see «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) and «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) .

Note. For individual mounting components for exhaust system to transmission on vehicles with automatic transmission 01J, see INDIVIDUAL LEFT MOUNTING COMPONENTS FOR VEHICLES WITH AUTOMATIC TRANSMISSION 01J .

ComponentNm
Front exhaust pipe with catalytic converter to exhaust manifold27
Front exhaust pipe with catalytic converter to hanging strap25
Mounting straps to transmission25
Drive axle protection to transmission23
Oxygen sensor to catalytic converter55
Engine mount to console23

TIGHTENING TORQUES: LH EXHAUST SYSTEM (A\T 01J)

  1. 3337 wrench, 7-piece set
  2. Engine/transmission hoist
  3. Locking compound G 052 112 A3

Scheme 7

Scheme 7: Removing
Scheme 7: Removing

Scheme 8

Scheme 8
Scheme 8
  1. Remove rear engine cover (arrows).
  2. Remove cover -1- in engine compartment (right side).
  3. Remove bolts (arrows).
  4. Detach Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- -1- at air guide.
  5. Remove air guide -2-.
  6. Remove air filter housing (arrows).
  7. Remove bolts for holding plate -3- for solenoid valves (arrows).
  8. Disconnect electrical harness connector at Mass Air Flow (MAF) sensor.
  9. Remove hose -4- from air duct -2-.
  10. Remove bolt (arrow) and disconnect air duct -2- at throttle valve control module.
  11. Disconnect hose -1- from air duct. NOTE: Illustration shows the air guide from rear with the engine removed.
  12. Remove harness connectors -1 to 4- from bracket at right of bulkhead.
  13. Disconnect electrical harness connectors -1- and -4-.
  14. Move wires to oxygen sensors clear.
  15. Unscrew oxygen sensor behind catalytic converter (arrow) using special tool 3337/7. NOTE: Illustration is shown with engine removed.
  16. Remove nut -2- for exhaust pipe/exhaust manifold which is accessible from top. NOTE: Illustration is shown with engine removed.
  17. Remove right front wheel
  18. For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater on noise insulation.
  19. Remove bolts or release quick-release screws -1- and -2- and remove front noise insulation.
  20. Remove quick-release screws -3- and remove rear noise insulation, if present.
  21. Remove bolts -1- through -4- and remove crossmember. NOTE: Flex joint in front exhaust pipe must not be bent more than 10°, otherwise it may be damaged.
  22. Disconnect exhaust system at both double clamps -arrows-.
  23. Remove VAG1359/2 universal mount from VAG1383A engine/gearbox jack and insert a piece of wood -1- instead.
  24. Support rear cross member using VAG1383A engine/transmission jack.
  25. First remove bolts -1- and -2-, then bolts -3- and -4-.
  26. Release slowly the rear cross member using VAG1383A engine/transmission jack.
  27. Set aside VAG1383A engine/transmission jack.
  28. Remove nuts (arrows) and rear cross member.
  29. Remove heat shield -1- for right drive axle.
  30. Remove right drive axle. See «FRONT AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__front-axle-shaft) .
  31. Remove bracket for front exhaust pipe (arrows).
  32. Unbolt bracket for ATF-lines (arrow). NOTE: Observe the rules of cleanliness for working on automatic transmissions: See «RULES FOR CLEANLINESS»(/audi/a4/b6-2000-2006/remont/automatic-trans/#automatic-transmission-overhaul-o1j-multitronic-cvt__rules-for-cleanliness) .
  33. Place oil pan underneath.
  34. Remove bolt (arrow) and disconnect ATF lines from transmission.
  35. Tie up ATF lines off to side.
  36. Expose oxygen sensor wire.
  37. Remove nuts -1- and -3- for front exhaust pipe/exhaust manifold which are accessible from bottom. NOTE: Illustration is shown with engine removed.
  38. Loosen lower nuts -1- (on left and right engine mounts) several turns.
  39. Press transmission to the left.
  40. Remove front exhaust pipe with catalytic converter.

Installation is reverse of removal, noting the following

Note. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation. Oxygen sensor threads are coated with an assembly paste. This paste must not contact sensor openings. Oxygen sensor wiring must always be secured in the same position when installing so that contact with the exhaust pipe is avoided. Replace gaskets and self-locking nuts.

  1. Secure ATF lines
  2. Install subframe: See «SUBFRAME & BUSHINGS»(/audi/a4/b6-2000-2006/remont/suspension-front/#suspension-front) .
  3. Install drive axle. See «FRONT AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__front-axle-shaft) .
  4. Install engine free of stress.
  5. Install exhaust system free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) and «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) . NOTE: For individual mounting components for exhaust system to transmission on vehicles with automatic transmission 01J, see «INDIVIDUAL RIGHT MOUNTING COMPONENTS FOR VEHICLES WITH AUTOMATIC TRANSMISSION 01J»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__individual-right-mounting-components-for-vehicles) .
  6. Check ATF level. See «SERVICING - A/T (01J)»(/audi/a4/b6-2000-2006/remont/automatic-trans/#automatic-transmission-servicing-at-01j-multitronic-cvt)
ComponentNm
Front exhaust pipe with catalytic converter to exhaust manifold27
Front exhaust pipe with catalytic converter to hanging strap25
Mounting straps to transmission25
Drive axle protection to transmission23
Oxygen sensor to catalytic converter55
Engine mount to console23

TIGHTENING TORQUES: RH EXHAUST SYSTEM (A\T 01J)

  1. 3337 wrench, 7-piece set
  2. Engine/transmission hoist
  3. Locking compound G 052 112 A3

Scheme 9

Scheme 9: Removing
Scheme 9: Removing

Scheme 10

Scheme 10
Scheme 10
  1. Remove rear engine cover (arrows).
  2. Remove cover -1- in engine compartment (right side).
  3. Remove bolts for holding plate -3- for solenoid valves (arrows).
  4. Disconnect intake air duct -1- at Mass Air Flow (MAF) sensor.
  5. Remove hose -4- for crankcase ventilation from air duct -2-.
  6. Remove bolt (arrow) and disconnect air duct -2- at throttle valve control module.
  7. Disconnect hose -1- from air duct. NOTE: Illustration shows the air guide from rear with the engine removed.
  8. Remove cover -1- in engine compartment (left side).
  9. Remove coolant reservoir (arrow)
  10. Disconnect electrical wiring to Engine Coolant Level (ECL) Warning Switch -F66- at bottom of coolant reservoir.
  11. Tie coolant reservoir with connected coolant hoses -1 to 3- to side.
  12. Disconnect vacuum hose to brake booster (arrows).
  13. Remove heat shield for harness connectors at left of bulkhead, if installed.
  14. Remove harness connectors -1 to 4- from bracket at left of bulkhead.
  15. Disconnect electrical harness connectors -1- and -4-.
  16. Move wires to oxygen sensors clear.
  17. Unscrew oxygen sensor behind catalytic converter (arrow) using special tool 3337/7. NOTE: Illustration is shown with engine removed.
  18. Remove nut -2- for exhaust pipe/exhaust manifold which is accessible from top. NOTE: Illustration is shown with engine removed.
  19. Remove left front wheel.
  20. For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater on noise insulation.
  21. Remove bolts or release quick-release screws -1- and -2- and remove front noise insulation.
  22. Remove quick-release screws -3- and remove rear noise insulation, if present.
  23. Remove bolts -1- through -4- and remove crossmember. NOTE: Flex joint in front exhaust pipe must not be bent more than 10°, otherwise it may be damaged..
  24. Disconnect exhaust system at both double clamps -arrows-.
  25. Remove heat shield above exhaust system.
  26. Remove heat shield for driveshaft from cover for Torsen differential (arrows).
  27. Remove bolts at flange of transmission/drive shaft.
  28. Push driveshaft to rear final drive together. The constant velocity joints can be adjusted axially.
  29. Rest driveshaft on exhaust system.
  30. Position engine/transmission jack VAG 1383 A directly behind ATF drip tray. Insert a wood block -1- to protect the transmission housing. WARNING: The lock carrier must be installed.
  31. First remove bolts -2- and -3- and then mounting bolts -1- and -4- of subframe.
  32. Slightly lower the transmission and subframe using VAG1383A engine/gearbox jack.
  33. Remove bolts 1 to 4 for transmission mount.
  34. Unbolt both transmission mounts -5- and -6- at transmission housing and remove transmission supports with transmission mounts.
  35. Lower transmission slowly.
  36. Remove heat shield -1- for left drive axle.
  37. Remove bracket for front exhaust pipe (arrow).
  38. Remove nuts -1- and -3- for front exhaust pipe/exhaust manifold which are accessible from bottom. NOTE: Illustration is shown with engine removed.
  39. Remove front exhaust pipe with catalytic converter.

Installation is reverse of removal, noting the following

Note. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation. Oxygen sensor threads are coated with an assembly paste. This paste must not contact sensor openings. Oxygen sensor wiring must always be secured in the same position when installing so that contact with the exhaust pipe is avoided. Replace gaskets and self-locking nuts.

Scheme 11

Scheme 11: Installing
Scheme 11: Installing

Scheme 12

Scheme 12
Scheme 12
  1. Install transmission supports. see scheme 112and see scheme 113. Tighten M10 bolts to 40 Nm. Tighten M6 bolts to 10 Nm. NOTE: Items (C) and (B) are not installed on vehicles with hydraulic transmission bearing (H), because bolt (G) is threaded directly into the transmission bearing. see scheme 113
  2. Install subframe: See «SUBFRAME & BUSHINGS»(/audi/a4/b6-2000-2006/remont/suspension-front/#suspension-front).
  3. Install drive axle shaft: See «FRONT AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__front-axle-shaft).
  4. Installing driveshaft: See «DRIVESHAFT»(/audi/a4/b6-2000-2006/remont/driveshaft-universal-joints/#driveshaft-universal-joints-01v-awd-transaxle).
  5. Install exhaust system free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) and «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress). NOTE: For individual mounting components for exhaust system to transmission on vehicles with automatic transmission 01V, see «INDIVIDUAL LEFT MOUNTING COMPONENTS FOR VEHICLES WITH AUTOMATIC TRANSMISSION 01V»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__individual-left-mounting-components-for-vehicles).
ComponentNm
Front exhaust pipe with catalytic converter to exhaust manifold27
Front exhaust pipe with catalytic converter to hanging strap25
Mounting straps to transmission25
Drive axle protection to transmission23
Oxygen sensor to catalytic converter55

TIGHTENING TORQUES: LH EXHAUST SYSTEM (A\T 01V)

  1. 3337 wrench, 7-piece set
  2. Engine/transmission hoist
  3. Locking compound G 052 112 A3

Scheme 13

Scheme 13: Removing
Scheme 13: Removing

Scheme 14

Scheme 14
Scheme 14
  1. Remove rear engine cover (arrows).
  2. Remove cover -1- in engine compartment (right side).
  3. Remove bolts (arrows).
  4. Detach Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- -1- at air guide.
  5. Remove air guide -2-.
  6. Remove air filter housing (arrows).
  7. Remove bolts for holding plate -3- for solenoid valves (arrows).
  8. Disconnect electrical harness connector at Mass Air Flow (MAF) sensor.
  9. Remove hose -4- of crankcase ventilation from air duct -2-.
  10. Remove bolt (arrow) and disconnect air duct -2- at throttle valve control module.
  11. Disconnect hose -1- from air duct. NOTE: Illustration shows the air guide from rear with the engine removed.
  12. Remove harness connectors -1 to 4- from bracket at right of bulkhead.
  13. Disconnect electrical harness connectors -1- and -4-.
  14. Move wires to oxygen sensors clear.
  15. Unscrew oxygen sensor behind catalytic converter (arrow) using special tool 3337/7. NOTE: Illustration is shown with engine removed.
  16. Remove nut -2- for exhaust pipe/exhaust manifold which is accessible from top. NOTE: Illustration is shown with engine removed.
  17. Remove right front wheel
  18. For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater on noise insulation.
  19. Remove bolts or release quick-release screws -1- and -2- and remove front noise insulation.
  20. Remove quick-release screws -3- and remove rear noise insulation, if present.
  21. Remove bolts -1- through -4- and remove crossmember. NOTE: Flex joint in front exhaust pipe must not be cant more than 10°, otherwise it may be damaged.
  22. Disconnect exhaust system at both double clamps - arrows-.
  23. Remove heat shield above exhaust system.
  24. Remove heat shield for driveshaft from cover for Torsen differential (arrows).
  25. Remove bolts at flange of transmission/drive shaft.
  26. Push driveshaft to rear final drive together. The constant velocity joints can be adjusted axially.
  27. Rest driveshaft on exhaust system.
  28. Position engine/transmission jack V.A.G 1383 A directly behind ATF drip tray. Insert a wood block -1- to protect the transmission housing. WARNING: The lock carrier must be installed.
  29. First remove bolts -2- and -3- and then mounting bolts -1- and -4- of subframe.
  30. Slightly lower the transmission and subframe using VAG 1383A engine/gearbox jack.
  31. Remove bolts -1- to -4- for transmission mount.
  32. Unbolt both transmission mounts -5- and -6- at transmission housing and remove transmission supports with transmission mounts.
  33. Lower transmission slowly.
  34. Remove heat shield -1- for right drive axle.
  35. Remove right drive axle. See «FRONT AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__front-axle-shaft) .
  36. Remove bracket for front exhaust pipe (arrow).
  37. Unbolt bracket for ATF-lines (arrow). NOTE: Observe the rules of cleanliness for working on automatic transmissions
  38. Place oil pan underneath.
  39. Remove bolt (arrow) and disconnect ATF-lines from transmission.
  40. Tie up ATF lines off to side.
  41. Expose oxygen sensor wire.
  42. Remove nuts -1- and -3- for front exhaust pipe/exhaust manifold which are accessible from bottom. NOTE: Illustration is shown with engine removed.
  43. Remove front exhaust pipe with catalytic converter.

Installation is reverse of removal, noting the following

Note. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation. Oxygen sensor threads are coated with an assembly paste. This paste must not contact sensor openings. Oxygen sensor wiring must always be secured in the same position when installing so that contact with the exhaust pipe is avoided. Replace gaskets and self-locking nuts.

  1. Install transmission supports. see scheme 138and. see scheme 139. Tighten M10 bolts to 40 Nm. Tighten M6 bolts to 10 Nm. NOTE: Items (C) and (B) are not installed on vehicles with hydraulic transmission bearing (H), because bolt (G) is threaded directly into the transmission bearing. see scheme 139
  2. Install subframe: See «SUBFRAME & BUSHINGS»(/audi/a4/b6-2000-2006/remont/suspension-front/#suspension-front)
  3. Install drive axle. See «FRONT AXLE SHAFT»(/audi/a4/b6-2000-2006/remont/axle-shafts/#axle-shafts-front-rear__front-axle-shaft)
  4. Installing driveshaft: See «DRIVESHAFT»(/audi/a4/b6-2000-2006/remont/driveshaft-universal-joints/#driveshaft-universal-joints-01v-awd-transaxle)
  5. Secure ATF lines
  6. Install exhaust system free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) and «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress). NOTE: For individual mounting components for exhaust system to transmission on vehicles with automatic transmission 01V, see «INDIVIDUAL RIGHT MOUNTING COMPONENTS FOR VEHICLES WITH AUTOMATIC TRANSMISSION 01V»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__individual-right-mounting-components-for-vehicles).
  7. Check ATF level. See «CHECKING FLUID LEVELS»(/audi/a4/b6-2000-2006/remont/automatic-trans/#servicing-at-01v-with-18l-30l__checking-fluid-levels).
ComponentNm
Front exhaust pipe with catalytic converter to exhaust manifold27
Front exhaust pipe with catalytic converter to hanging strap25
Mounting straps to transmission25
Drive axle protection to transmission23
Oxygen sensor to catalytic converter55

TIGHTENING TORQUES: RH EXHAUST SYSTEM (A\T 01V)

  1. Remove left front exhaust pipe with catalytic converter. See «LEFT FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER, REMOVING AND INSTALLING (VEHICLES WITH MANUAL TRANSMISSION)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) , «LEFT FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER, REMOVING AND INSTALLING (VEHICLES WITH AUTOMATIC TRANSMISSION 01J)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) and «LEFT FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER, REMOVING AND INSTALLING (VEHICLES WITH AUTOMATIC TRANSMISSION 01V)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) .
  2. Remove threaded connection -2- at heat shield which is accessible from bottom.
  3. Unscrew threaded connection -1- which is accessible from top and remove heat shield.
  4. Unscrew threaded connections -1- of exhaust manifold which is accessible from top.
  5. Remove nuts -2- from bottom and remove heat shield bracket.
  6. Remove nut -3- and remove exhaust manifold.

Installation is reverse of removal, noting the following

Note. Replace gaskets and self-locking nuts.

  1. Install left front exhaust pipe with catalytic converter. See «INSTALLING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__installing) , «INSTALLING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) and «INSTALLING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) .
  2. Install exhaust system free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) and «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) .

Scheme 15

Scheme 15: Tightening torques
Scheme 15: Tightening torques
  1. Remove right front exhaust pipe with catalytic converter. See «RIGHT FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER, REMOVING AND INSTALLING (VEHICLES WITH MANUAL TRANSMISSION)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) , «RIGHT FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER, REMOVING AND INSTALLING (VEHICLES WITH AUTOMATIC TRANSMISSION 01J)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) and «RIGHT FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER, REMOVING AND INSTALLING (VEHICLES WITH AUTOMATIC TRANSMISSION 01V)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) .
  2. Remove threaded connection -2- at heat shield which is accessible from bottom.
  3. Unscrew threaded connection -1- which is accessible from top.
  4. Remove bolts -1- and -2- at secondary air injection lines. NOTE: Resonator -4- remains installed with bolts -3- and -5-.
  5. Remove bolts -1- and -3-.
  6. Disconnect hose -4- from secondary air injection line.
  7. Pull out guide tube for oil dipstick -2- toward top from the oil pan (upper part) and swing it forward.
  8. Remove heat shield.
  9. Unscrew threaded connection -1- on exhaust manifold which is accessible from top.
  10. Remove nuts -2- from bottom and remove heat shield bracket.
  11. Remove nut -3- and remove exhaust manifold.

Installation is reverse of removal, noting the following

Note. Replace gaskets and self-locking nuts.

  1. Replace O-ring at guide tube for oil dipstick and insert guide tube into hole in oil pan (upper part).
  2. Install right front exhaust pipe with catalytic converter. See «INSTALLING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) , «INSTALLING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) or «INSTALLING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) .
  3. Align exhaust system free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) or «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) .

Tightening torque

ComponentNm
Exhaust manifold to cylinder head25
Heat shield to heat shield bracket10
Tube for Secondary Air Injection
M610
M825
Guide tube for oil dipstick to line for secondary air injection10

TIGHTENING TORQUES: RH EXHAUST MANIFOLD

Exhaust system, aligning free of stress (front wheel drive vehicles)

Note. Align exhaust system when cold.

Scheme 16

Scheme 16: Exhaust system, aligning free of stress (front wheel drive vehicles)
Scheme 16: Exhaust system, aligning free of stress (front wheel drive vehicles)

Scheme 17

Scheme 17
Scheme 17
  1. Remove bolts -1- through -4- and remove crossmember (55 Nm). Vehicles without clamping sleeve between center and rear muffler
  2. Loosen double clamp bolts. See «EXHAUST SYSTEM COMPONENTS, OVERVIEW (FRONT WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-components-overview-front-wheel) , Item -14-.
  3. Push exhaust system far enough forward (arrow) so that the pre-tension at the retaining loop at center muffler a = 5 to 9 mm.
  4. Tighten double clamp bolts uniformly to 40 Nm.
  5. Align end pipes. See «TAILPIPES, ALIGNING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__tailpipes-aligning) . Vehicles with clamping sleeve between center and rear muffler NOTE: Only for vehicles with double clamp between center and rear mufflers, the rear muffler must also be aligned.
  6. Loosen double clamp bolts. See «EXHAUST SYSTEM COMPONENTS, OVERVIEW (FRONT WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-components-overview-front-wheel) , Items -14- and -23-.
  7. Push front part of exhaust system far enough forward (arrow) so that the pre-tension at the retaining loop at center muffler a = 5 to 9 mm.
  8. Tighten front double clamp bolts (see «EXHAUST SYSTEM COMPONENTS, OVERVIEW, (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-components-overview-all-wheel) , Item -14-) evenly to 40 Nm.
  9. Push rear part of exhaust system far enough forward (arrow) so that the pre-tension at rear retaining loops at rear muffler a = 7 to 11 mm.
  10. Align rear muffler horizontally.
  11. Tighten rear double clamp bolts (see «EXHAUST SYSTEM COMPONENTS, OVERVIEW (FRONT WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-components-overview-front-wheel) , Item -23-) evenly to 40 Nm.
  12. Align end pipes, see «Tailpipes, aligning»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__tailpipes-aligning) .

Exhaust system, aligning free of stress (all wheel drive vehicles)

Note. Align exhaust system when cold.

Scheme 18

Scheme 18: Exhaust system, aligning free of stress (all wheel drive vehicles)
Scheme 18: Exhaust system, aligning free of stress (all wheel drive vehicles)
  1. Remove bolts -1- through -4- and remove crossmember (55 Nm). Vehicles without clamping sleeve between center and rear muffler
  2. Loosen double clamp bolts. See «EXHAUST SYSTEM COMPONENTS, OVERVIEW, (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-components-overview-all-wheel) , Item -14-.
  3. Push exhaust system far enough forward (arrow) so that the pre-tension at the right retaining loop at center muffler a = 5 to 9 mm.
  4. Tighten double clamp bolts uniformly to 40 Nm.
  5. Align end pipes, see «TAILPIPES, ALIGNING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__tailpipes-aligning) . Vehicles with clamping sleeve between center and rear muffler NOTE: Only for vehicles with double clamp between center and rear mufflers, the center muffler must also be aligned.
  6. Loosen double clamp bolts. See «EXHAUST SYSTEM COMPONENTS, OVERVIEW, (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-components-overview-all-wheel) , Items -14- and -24-.
  7. Push front part of exhaust system far enough forward (arrow) so that the pre-tension at the retaining loop at center muffler a = 5 to 9 mm.
  8. Tighten front double clamp bolts (see «EXHAUST SYSTEM COMPONENTS, OVERVIEW, (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-components-overview-all-wheel) , Item -14-) evenly to 40 Nm.
  9. Push rear part of exhaust system far enough forward (arrow) so that the pre-tension at rear retaining loops at rear muffler a = 7 to 11 mm.
  10. Align rear muffler horizontally.
  11. Tighten rear double clamp bolts (see «EXHAUST SYSTEM COMPONENTS, OVERVIEW, (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-components-overview-all-wheel) , Item -24-) evenly to 40 Nm.
  12. Align end pipes, see «TAILPIPES, ALIGNING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__tailpipes-aligning) .

Tailpipes, aligning

  1. Check distance of end pipes at left and right to bumper: Dimension x left = dimension x right If necessary, correct dimension x as follows
  2. Loosen nuts (arrows) of brace between exhaust pipes.
  3. Change the distance of the rear mufflers to each other.
  4. Tighten nut to 23 Nm.
  5. Check distances -y- and -z- of end pipes to bumper: Dimension y = greater than 20 mm Dimension z = 9 to 14 mm
  6. If necessary, check whether the exhaust system is installed free of stress. See «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) or «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__exhaust-system-aligning-free-of-stress) .

Exhaust system, checking for proper seal

  1. Start engine and let run at idle.
  2. Seal tailpipes with cloths or plug for the duration of the leak test.
  3. Check for leaks by listening at cylinder head/exhaust manifold, exhaust manifold/front exhaust pipe etc.
  4. Repair leaks.

Secondary air system

The Secondary Air Injection (AIR) system causes the catalytic converter to heat up more quickly, resulting in earlier operating readiness following cold start.

Principle

Due to over-enrichment of the mixture during the cold start phase, there is an increased amount of uncombusted carbon monoxide in the exhaust. Secondary Air Injection (AIR) improves secondary oxidation in the catalytic converter and therefore reduces emissions. The heat produced by secondary oxidation greatly reduces start-up time for the catalytic converter, therefore improving exhaust quality during the cold start phase significantly.

Function

  1. In the cold start phase, the ECM -4- activates the secondary air pump -2- via the relay for secondary air injection -3-. Air reaches the combination valves for Secondary Air Injection (AIR) -5- and -9-.
  2. The Secondary Air Injection (AIR) valve -6- is activated in parallel, which allows the vacuum to reach the combination valves for Secondary Air Injection (AIR) -5- and -9-. The appropriate combination valve for Secondary Air Injection (AIR) thereby opens the path for secondary air to the exhaust channels of the cylinder head.

Scheme 19

Scheme 19
Scheme 19

The following list pertains to see scheme 158.

  1. From air filter housing
  2. Secondary Air Injection (AIR) Pump Motor -V101- Component location, see «SECONDARY AIR INJECTION (AIR) PUMP MOTOR -V101»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__secondary-air-injection-air-pump-motor) Removing and installing, see «SECONDARY AIR INJECTION (AIR) PUMP MOTOR - V101-, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk)
  3. Secondary Air Injection (AIR) Pump Relay -J299- Component location, see «SECONDARY AIR INJECTION (AIR) PUMP RELAY -J299»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__secondary-air-injection-air-pump-relay)
  4. Motronic Engine Control Module (ECM) -J220
  5. Combination valve for secondary air injection (right) Component location, see «COMBINATION VALVE FOR SECONDARY AIR INJECTION (AIR)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__combination-valve-for-secondary-air-injection) Checking, see «COMBINATION VALVE FOR SECONDARY AIR INJECTION (AIR), CHECKING FUNCTION AND PROPER SEAL»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) Removing and installing, see «RIGHT COMBINATION VALVE FOR SECONDARY AIR INJECTION, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk)
  6. Secondary Air Injection (AIR) Solenoid Valve -N112- Component location, see «COMPONENT LOCATION SECONDARY AIR INJECTION (AIR) SOLENOID VALVE -N112»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__component-location-secondary-air-injection-air)
  7. Check-valve Installed position (light/dark side): Arrow points in direction of flow, as shown in figure.
  8. To Intake manifold
  9. Combination valve for secondary air injection (left) Component location, see «COMBINATION VALVE FOR SECONDARY AIR INJECTION (AIR)»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk__combination-valve-for-secondary-air-injection) Checking, see «COMBINATION VALVE FOR SECONDARY AIR INJECTION (AIR), CHECKING FUNCTION AND PROPER SEAL»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) Removing and installing, see «LEFT COMBINATION VALVE FOR SECONDARY AIR INJECTION, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk)
  10. Vacuum reservoir Installation location: Under wheel housing liner in front left wheel housing

Component location Secondary Air Injection (AIR) Solenoid Valve -N112

Component location Secondary Air Injection (AIR) Solenoid Valve -N112

  1. Bolted to holding plate for solenoid valves at rear of engine (arrow).

Secondary Air Injection (AIR) Pump Motor -V101

  1. At front right in engine compartment below air filter housing
  1. Secondary Air Injection (AIR) Pump Motor -V101
  2. Electrical harness connector for Secondary Air Injection (AIR) Pump Motor -V101

Secondary Air Injection (AIR) Pump Relay -J299

  1. In E-box, plenum chamber 3 - Secondary Air Injection (AIR) Pump Relay -J299- B - Fuse for secondary air pump -S130

Combination valve for secondary air injection (AIR)

  1. At rear of cylinder heads NOTE: Right valve is shown in illustration.
  1. VAG1526A
  2. VAG1527B
  3. Vag1594A
  4. Vag1598/31
  5. Vas5051 With Vag5051/1

Test Requirement

  1. Vas5051 Tester Connected And Vehicle On Board Diagnostic (Obd) Function 01 "Engine Electronics" Selected.

Test Sequence

Note. Secondary Air Injection (Air) Solenoid Valve -N112- And Wire Connections Are Monitored By The Engine Control Module (Ecm).

  1. Check Dtc Memory Of Engine Control Module (ECM). If A Malfunction Regarding Secondary Air Injection (Air) Solenoid Valve -N112- Is Displayed
  2. Remove Rear Engine Cover (Arrows).
  3. Disconnect Hoses From Secondary Air Injection (Air) Solenoid Valve -N112- (Arrow); The Electrical Harness Connector Remains Connected.
  4. Attach assisting hose to the connection of valve (indicated by an arrow).
  5. Initiate output Diagnostic Test Mode (DTM) and activate Secondary Air Injection (AIR) Solenoid Valve -N112-: Valve must click. ...and must open and close (can be tested by blowing into assisting hose). If valve does not open or close properly
  6. Replace Secondary Air Injection (AIR) Solenoid Valve -N112-. If valve does not click during output Diagnostic Test Mode (DTM)

Scheme 20

Scheme 20: Checking internal resistance
Scheme 20: Checking internal resistance
  1. Switch ignition off.
  2. Disconnect harness connector from Secondary Air Injection (AIR) Solenoid Valve -N112- (arrow).
  3. Connect multimeter at valve for resistance measurement. Specification: 25 to 35 ohm If specified value is not obtained
  4. Replace Secondary Air Injection (AIR) Solenoid Valve -N112-. If specified value is obtained

Test requirements

  1. Fuse for Secondary Air Injection (AIR) OK See appropriate System Wiring Diagram article
  2. Fuel Pump (FP) relay OK

Voltage supply check

Note. Voltage is supplied to Secondary Air Injection (AIR) Solenoid Valve -N112- via the Fuel Pump (FP) relay.

  1. Connect VAG1527B voltage tester as follows: CHECKING VOLTAGE SUPPLY CIRCUIT TO SECONDARY AIR INJECTION (AIR) SOLENOID VALVE Harness Connector Terminal Measure to 1 Engine Ground (GND)
  2. Operate starter briefly. LED must light up. If LED does not light up
  3. Check wire connection from terminal 1 of connector to Fuel Pump (FP) relay via fuse for open circuit: See appropriate System Wiring Diagram
  4. Repair open circuit if necessary. If LED lights up

Checking activation

  1. Connect VAG1527B voltage tester to connector terminals 1 (B+) and 2.
  2. Initiate output Diagnostic Test Mode (DTM) and activate Secondary Air Injection (AIR) Solenoid Valve -N112-: LED must blink. If LED does not blink or if it remains constantly lit
  3. Connect VAG 1598/31 test box to harness connectors of wiring harness (do not connect ECM). Connect Ground (GND) clip at test box (not visible in see scheme 171 ) to Ground (GND). See «WIRING AND COMPONENT CHECK WITH TEST BOX VAG»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-30l-avk__wiring-and-component-check-with-test).
  4. Check the following wire connection for open circuit and short circuit to Ground (GND) and B+: CHECKING ACTIVATION CIRCUIT FOR SECONDARY AIR INJECTION (AIR) SOLENOID VALVE Harness connector terminal VAG1598/31 test box socket 2 44
  5. Repair open circuit or short circuit if necessary.
  1. VAG1526A
  2. VAG1527B
  3. VAG1594A
  4. VAG1598/31
  5. VAS5051 with VAG5051/1
  1. VAS5051 tester connected and vehicle On Board Diagnostic (OBD) function 01 "Engine electronics" selected.
  1. Initiate output Diagnostic Test Mode (DTM) and activate Secondary Air Injection (AIR) Pump Relay -J299-. Secondary Air Injection (AIR) Pump Relay -3- (in E-box, plenum chamber) must engage and Secondary Air Injection (AIR) Pump Relay -J299- must run in intervals A - does not engage the relay
  2. See «CHECKING VOLTAGE SUPPLY OF SECONDARY AIR INJECTION (AIR) PUMP RELAY»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk)
  3. Checking activation of Secondary Air Injection (AIR) Pump Relay, see «CHECK ACTIVATION OF THE SECONDARY AIR INJECTION (AIR) PUMP RELAY»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) . B - If relay triggers, but Secondary Air Injection (AIR) Pump Motor does not run
  4. Checking voltage supply of Secondary Air Injection (AIR) Pump Motor, see «CHECK VOLTAGE SUPPLY OF THE SECONDARY AIR INJECTION (AIR) PUMP MOTOR»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) .

Scheme 21

Scheme 21: Checking voltage supply of Secondary Air Injection (AIR) Pump Relay
Scheme 21: Checking voltage supply of Secondary Air Injection (AIR) Pump Relay

Scheme 22

Scheme 22
Scheme 22
  1. Switch ignition off.
  2. Pull off rubber seal from plenum chamber cover in direction of arrow.
  3. Remove plenum chamber cover -1- toward front.
  4. Pry off both covers -3- using a screwdriver.
  5. Loosen hex-nuts -4- by several turns.
  6. Loosen wiper arm -2- by lightly tilting from wiper axle.
  7. Remove hex nuts completely and remove wiper arms.
  8. Disconnect securing clips -1- and remove cowl grill -5-.
  9. Remove E-box cover in plenum chamber -arrows-.
  10. Pry off Engine Control Module (ECM) retaining bracket (arrows) using a screwdriver and set control module aside.
  11. If installed, unclip Transmission Control Module (TCM) retaining bracket and set control module aside.
  12. Remove Secondary Air Injection (AIR) pump relay -3-.
  13. Connect multimeter for voltage measurement as follows SECONDARY AIR INJECTION (AIR) PUMP RELAY VOLTAGE REFERENCE Relay carrier in E-box, plenum chamber, Measure to position 3 Terminal 8 Engine Ground (GND) Specification: approx. battery voltage If specified value is not obtained
  14. Perform the following tests marked with dots: Check Fuse for secondary air pump -S130- (40 A) in E-Box, plenum chamber, position B. Check wire connection from battery + (terminal 30) via Fuse for secondary air pump -S130- to Secondary Air Injection (AIR) Pump Relay -J299- (in relay and fuse carrier in E-Box, plenum chamber, position 3) for open circuit.
  15. Connect multimeter for voltage measurement as follows. SECONDARY AIR INJECTION (AIR) PUMP RELAY VOLTAGE REFERENCE Relay carrier in E-box, plenum chamber, Measure to position 3 Terminal 4 Engine Ground (GND)
  16. Operate starter briefly. Specification: approx. battery voltage If specified value is not obtained
  17. Perform the following tests marked with dots: Check fuse -S234- in fuse holder (position 34). Check wire connection from Secondary Air Injection (AIR) Pump Relay -J299- (in 3-socket relay carrier in E-box, plenum chamber) via Fuse in fuse holder -S234- (position 34) to Fuel Pump (FP) relay for open circuit.

Scheme 23

Scheme 23: Check activation of the Secondary Air Injection (AIR) pump relay
Scheme 23: Check activation of the Secondary Air Injection (AIR) pump relay
  1. Switch ignition off.
  2. Remove Secondary Air Injection (AIR) pump relay
  3. Connect VAG1527B voltage tester as follows: SECONDARY AIR INJECTION (AIR) PUMP RELAY ACTIVATION REFERENCE Relay carrier in E-box, plenum chamber Measure to position 3 Terminal 6 Engine Ground (GND)
  4. Initiate output Diagnostic Test Mode (DTM) and activate Secondary Air Injection (AIR) Pump Relay -J299-. LED must blink. If LED does not blink
  5. Switch ignition off.
  6. Connect VAG1598/31 test box to harness connectors of wiring harness (do not connect ECM). Connect Ground (GND) clip at test box (not visible in illustration) to Ground (GND). See «WIRING AND COMPONENT CHECK WITH TEST BOX VAG»(/audi/a4/b6-2000-2006/remont/fuel-system/#multiport-fuel-injection-mfi-30l-avk__wiring-and-component-check-with-test)
  7. Check the following wire connection for open circuit and short circuit to Ground (GND) and B+: SECONDARY AIR INJECTION (AIR) PUMP RELAY OPEN AND SHORT CIRCUIT REFERENCE Relay carrier in E-box VAG1598/31 test box plenum chamber, Socket position 3 Terminal 6 46
  8. Repair open circuit or short circuit if necessary. If no malfunctions are detected
  9. Replace Secondary Air Injection (AIR) Pump Relay -J299-.

Scheme 24

Scheme 24: Check voltage supply of the Secondary Air Injection (AIR) pump motor
Scheme 24: Check voltage supply of the Secondary Air Injection (AIR) pump motor
  1. For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater at noise insulation.
  2. Remove bolts or release quick-release screws -1- and -2- and remove front noise insulation.
  3. Disconnect electrical harness connector -2- at Secondary Air Injection (AIR) Pump Motor -V101- -Item 1-.
  4. Connect VAG1527B voltage tester between terminals 1 and 2
  5. Initiate output Diagnostic Test Mode (DTM) and activate Secondary Air Injection (AIR) Pump Relay -J299-. LED must blink. If LED does not blink
  6. Perform the following tests marked with dots: Check wire connection from terminal 2 of connector to Secondary Air Injection (AIR) Pump Relay -J299- (in relay carrier in E-Box, plenum chamber, position 3) for open circuit. See appropriate System Wiring Diagrams article Check wire connection from terminal 1 of connector to Ground (GND) for open circuit: See appropriate System Wiring Diagrams article If no malfunctions are detected: Replace Secondary Air Injection (AIR) Pump Motor - V101-.
  1. Remove cover -1- in engine compartment (right side).
  2. Remove bolts (arrows).
  3. Detach Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- -1- at air guide.
  4. Remove air guide -2-.
  5. Remove air filter housing (arrows).
  6. Remove both bolts on secondary Air Injection (AIR) pump bracket, which are accessible from top.
  7. For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater at noise insulation.
  8. Remove bolts or release quick-release screws -1- and -2- and remove front noise insulation.
  9. Disconnect electrical harness connector -3-.
  10. Disconnect air hoses -1- and -2-.
  11. Remove bolts for secondary Air Injection (AIR) pump bracket, which are accessible from bottom.
  12. Remove Secondary Air Injection (AIR) Pump Motor -V101- with bracket.
  13. If necessary, separate Secondary Air Injection (AIR) Pump Motor -V101- from bracket.

Installation is the reverse of removal.

ComponentNm
Motor for Secondary Air Injection (AIR) to bracket10
Bracket for motor for Secondary Air Injection (AIR) to chassis10

TIGHTENING TORQUES: SECONDARY AIR INJECTION (AIR) PUMP MOTOR

  1. VAG1390 hand vacuum pump
  1. Vacuum lines and hose connections leak-free.
  2. Vacuum lines not clogged.
  1. Remove rear engine cover (arrows).
  2. Remove bolts for holding plate for solenoid valves (arrows).
  3. Lift up holding plate and disconnect vacuum hose from Y-piece of combination valve to be checked.
  4. Connect VAG1390 hand vacuum pump to vacuum hose of combination valve to be checked.
  5. For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater at noise insulation.
  6. Remove bolts or release quick-release screws -1- and -2- and remove front noise insulation.
  7. Disconnect pressure hose (arrow) at Secondary Air Injection (AIR) Pump Motor and blow into it with light pressure (do not use pressurized air). Both combination valves must be closed, it must not be possible to blow through hose
  8. Operate hand vacuum pump. The relevant combination valve must open, it must be possible to blow through If the relevant combination valve does not open
  9. Replace combination valve. See «LEFT COMBINATION VALVE FOR SECONDARY AIR INJECTION, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) or «RIGHT COMBINATION VALVE FOR SECONDARY AIR INJECTION, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exhaust/#exhaust-system-emission-controls-30l-avk) .
  1. Remove rear engine cover (arrows).
  2. Remove bolts for holding plate -3- for solenoid valves (arrows).
  3. Disconnect intake air hose -1- at Mass Air Flow (MAF) sensor.
  4. Disconnect hose -4- for crankcase ventilation from air guide -2-.
  5. Remove bolt (arrow) and disconnect air guide -2- at throttle valve control module.
  6. Disconnect hose -1- from air guide. NOTE: Illustration shows the air guide from rear with the engine removed.
  7. Remove cover -1- in engine compartment (left side).
  8. Clamp coolant hose -2- using 3094 hose clamps and disconnect coolant hose from coolant reservoir.
  9. Unbolt coolant reservoir (arrow).
  10. Disconnect electrical wiring to Engine Coolant Level (ECL) Warning Switch -F66- at bottom of coolant reservoir.
  11. Lay coolant reservoir with connected coolant hoses -1- and -3- to side.
  12. Disconnect electrical harness connectors -1- and -2- at Camshaft Position (CMP) Sensor 2 -G163- and Camshaft Position (CMP) Sensor 4 -G301-.
  13. Disconnect hose -3- from crankcase ventilation at cylinder head cover.
  14. Remove bolts -1- at flange of combination valve for secondary air injection.
  15. Loosen nut -3- several turns.
  16. Remove bolts -2- and disconnect vacuum hose (arrow).
  17. Remove combination valve.

Note. Illustration is shown with engine removed.

Installation is reverse of removal, noting the following

Note. Replace gaskets and O-rings.

  1. Top off coolant. See «COOLANT, DRAINING AND REFILLING»(/audi/a4/b6-2000-2006/remont/cooling-fan/#engine-cooling-30l-6-cylinder-5v-avk) .

Scheme 25

Scheme 25: Tightening torques
Scheme 25: Tightening torques

Scheme 26

Scheme 26: Removing
Scheme 26: Removing
  1. Remove rear engine cover (arrows).
  2. Remove cover -1- in engine compartment (right side).
  3. Remove bolts for holding plate -3- for solenoid valves (arrows).
  4. Disconnect intake air hose -1- at Mass Air Flow (MAF) sensor.
  5. Disconnect hose -4- for crankcase ventilation from air guide -2-.
  6. Remove bolt (arrow) and disconnect air guide -2- at throttle valve control module.
  7. Disconnect hose -1- from air guide. NOTE: Illustration shows the air guide from rear with the engine removed.
  8. Unscrew bolts -1- and -2- and remove combination valve.
  9. Disconnect vacuum hose (arrow).

Installation is reverse of removal, noting the following

Note. Replace gaskets and O-rings.

ComponentNm
Combination valve to cylinder head10
Connecting tube to combination valve10

TIGHTENING TORQUES: SECONDARY AIR INJECTION COMBINATION VALVE

See also:
• SUBFRAME & BUSHINGS
• FRONT AXLE SHAFT
• RULES FOR CLEANLINESS
• SERVICING - A/T (01J)
• DRIVESHAFT
• CHECKING FLUID LEVELS
• WIRING AND COMPONENT CHECK WITH TEST BOX VAG
• COOLANT, DRAINING AND REFILLING
• Procedure
• EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)
• RIGHT EXHAUST MANIFOLD, REMOVING AND INSTALLING
• INDIVIDUAL LEFT MOUNTING COMPONENTS FOR VEHICLES WITH MANUAL TRANSMISSION
• INSTALLED POSITION OF FRONT CLAMPING SLEEVES
• INDIVIDUAL RIGHT MOUNTING COMPONENTS FOR VEHICLES WITH MANUAL TRANSMISSION
• REPLACING END PIPE
• INSTALLED POSITION OF REAR CLAMPING SLEEVES
• INSTALLING
• EXHAUST SYSTEM COMPONENTS, OVERVIEW (FRONT WHEEL DRIVE VEHICLES)
• TAILPIPES, ALIGNING
• EXHAUST SYSTEM COMPONENTS, OVERVIEW, (ALL WHEEL DRIVE VEHICLES)
• SECONDARY AIR INJECTION (AIR) PUMP MOTOR -V101
• SECONDARY AIR INJECTION (AIR) PUMP RELAY -J299
• COMBINATION VALVE FOR SECONDARY AIR INJECTION (AIR)
• COMPONENT LOCATION SECONDARY AIR INJECTION (AIR) SOLENOID VALVE -N112

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