3.2l - Exhaust System, Emission Controls - Engine Code(s): Cala (coupe) (as of 11.2007) Audi A5 I

Scheme 18

1. Nut Replace Grease with hot bolt paste; Hot bolt paste Tightening specifications and sequence: Left (Scheme 19), right (Scheme 20)
2. Bracket for heat shield
3. Exhaust manifold Removing and installing: Left «LEFT EXHAUST MANIFOLD»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007), right «RIGHT EXHAUST MANIFOLD»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007)
4. Gasket Replace
5. Heat shield
6. Bolt 10 Nm
7. Oxygen sensor Before catalytic converter Threads of new oxygen sensors are coated with assembly paste When reinstalling a used oxygen sensor, coat threads with hot bolt paste; hot bolt paste Assembly paste or hot bolt paste must not get onto slots of sensor body. Removing and installing «Removal and Installation»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
8. Catalytic converter Protect from shocks and impact stress Removing and installing: Left: «LEFT CATALYTIC CONVERTER»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007). Right, with manual transmission: «RIGHT CATALYTIC CONVERTER»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007). Right, with automatic transmission: «RIGHT CATALYTIC CONVERTER»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007).
9. Nut Replace Grease with hot bolt paste. 23 Nm
10. Gasket Replace

Scheme 19

Tighten nuts in 3 stages in -1 to 9- sequence as follows

Scheme 20

Tighten nuts in 3 stages in -1 to 9- sequence as follows

Scheme 21

1. Bolt 23 Nm
2. Suspended mount Replace if damaged Check pretension «EXHAUST SYSTEM, INSTALLING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007__exhaust-system-installing).
3. Center muffler Original equipment as one unit with rear mufflers. For repairs, replace each separately. Separating point «CENTER AND REAR MUFFLERS, SEPARATING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007__center-and-rear-mufflers-separating). Install exhaust system free of stress «EXHAUST SYSTEM, INSTALLING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007__exhaust-system-installing).
4. Rear muffler Original equipment as one unit with center muffler and tailpipe In case of repairs, center muffler end muffler and tailpipe should be replaced individually Separating point between center and rear muffler «CENTER AND REAR MUFFLERS, SEPARATING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007__center-and-rear-mufflers-separating). Separating point between rear muffler and tailpipe «TAIL PIPE»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007__tail-pipe). Install exhaust system free of stress «EXHAUST SYSTEM, INSTALLING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007__exhaust-system-installing).
5. Gasket Replace
6. Nut 23 Nm
7. Catalytic converter Protect from shocks and impact stress Removing and installing: Left: «LEFT CATALYTIC CONVERTER»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007). Right, with manual transmission: «RIGHT CATALYTIC CONVERTER»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007). Right, with automatic transmission: «RIGHT CATALYTIC CONVERTER»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007). Individual components of suspension (Scheme 24)
8. Nut 23 Nm
9. Gasket Replace
10. Front muffler With decoupling element, do not bend the decoupling element more than 10 degrees or it could be damaged Removing and installing «FRONT MUFFLER»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007). Install exhaust system free of stress «EXHAUST SYSTEM, INSTALLING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007__exhaust-system-installing).
11. Front clamping sleeve Installed location (Scheme 22) Before tightening, align exhaust system tension-free «EXHAUST SYSTEM, INSTALLING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007__exhaust-system-installing). Tighten threaded connections evenly.
12. Nut 23 Nm
13. Bolt 23 Nm
14. Clamp
15. End pipe Original equipment as one unit with rear muffler. For repairs, replace each separately. Separating point «TAIL PIPE»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007__tail-pipe). Aligning «TAIL PIPES, ALIGNING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007__tail-pipes-aligning).
16. Suspended mount Replace if damaged Check pretension «EXHAUST SYSTEM, INSTALLING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007__exhaust-system-installing).
17. Nut Replace 20 Nm
18. Rear clamping sleeve For individual replacement of center and rear mufflers Installed location (Scheme 22) Before tightening, align exhaust system tension-free «EXHAUST SYSTEM, INSTALLING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007__exhaust-system-installing). Tighten threaded connections evenly.
19. Nut 23 Nm
20. Nut Replace 23 Nm
21. Bolt 23 Nm
22. Suspended mount Replace if damaged Check pretension «EXHAUST SYSTEM, INSTALLING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007__exhaust-system-installing).

Scheme 22

Install double clamps so that the bolt ends do not project over lower edge of double clamp.

1. Installation position: Threaded connections point toward outside.

Scheme 23

Install double clamps so that the bolt ends do not project over lower edge of double clamp.

1. Installation position: Threaded connections point forward.

Scheme 24

1. Nut - 23 Nm
2. Spacing sleeve
3. Spring
4. Washer
5. Bolt
6. Bolt - 23 Nm
7. Spacing sleeve
8. Buffer
9. Mounting tab
10. Bolt - 23 Nm
11. Bracket

Note. The illustration shows the right mounting. The left is a mirror image of the right.

LEFT EXHAUST MANIFOLD NUT TIGHTENING SEQUENCE AND SPECIFICATION

Tighten nuts in 3 stages in -1 to 9- sequence as follows

Install bolts by hand as far as stop.

Pre-tighten to 15 Nm.

Tighten to 25 Nm.

RIGHT EXHAUST MANIFOLD NUT TIGHTENING SEQUENCE AND SPECIFICATION

Tighten nuts in 3 stages in -1 to 9- sequence as follows

Install bolts by hand as far as stop.

Pre-tighten to 15 Nm.

Tighten to 25 Nm.

EXHAUST SYSTEM, CHECKING FOR LEAKS

Proceed as follows

Start engine and let it run at idle.

Seal exhaust pipes with cloths or plugs during leak test.

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

Repair detected leaks.

REMOVING

Proceed as follows

Remove left catalytic converter LEFT CATALYTIC CONVERTER .

Remove air conditioner compressor Removal and Installation .

Remove the Heated Oxygen Sensor (HO2S) -G108- Removal and Installation .

Remove left engine mount LEFT ENGINE MOUNT .

Remove bolts -arrows- and left engine support.

Scheme 25

Remove bolts -1 through 4- and remove heat shield.

Scheme 26

Remove nuts -1- and -8- and heat shield bracket.

Scheme 27

Remove nuts -2 through 7- and -9- and remove the exhaust manifold.

INSTALLING

1. Tightening specifications (Scheme 19)

Installation is in reverse order of removal, note the following

Note. Replace seal and self-locking nuts.

Position exhaust manifold with catalytic converter seal and tighten nuts (Scheme 19)

Install engine supports with left engine mount LEFT ENGINE MOUNT .

Install Heated Oxygen Sensor (HO2S) 2 -G108- Removal and Installation .

Install A/C compressor Removal and Installation .

Install left catalytic converter LEFT CATALYTIC CONVERTER .

Install left front muffler FRONT MUFFLER .

Install noise insulation Description and Operation .

Install plenum chamber bulkhead Description and Operation .

Proceed as follows

Remove noise insulation by loosening fasteners -1 through 4-.

Scheme 28

Note. Ignore -arrow-.

Remove heated oxygen sensor (HO2S) -G39- Removal and Installation .

Remove plenum chamber bulkhead Description and Operation .

Remove right front muffler FRONT MUFFLER .

With Manual Transmission

Remove nuts -arrows- and bolt -1- and press right catalytic converter to the side.

Scheme 29

Note. The installation location is shown with the engine removed.

With Automatic Transmission

Remove right catalytic converter RIGHT CATALYTIC CONVERTER

Continuation for All

Scheme 30

Remove right front wheel.

Remove right front wheel housing liner Description and Operation .

Remove nut -1- and bolt -2- and press coolant pipe to side.

Note. Ignore -arrows-.

Remove bolts -1 through 4- and remove heat shield.

Scheme 31

Remove nuts -7- and -9- and heat shield bracket.

Scheme 32

Remove nuts -1 through 6- and -8- and exhaust manifold.

1. Tightening specifications (Scheme 20)

Installation is in reverse order of removal, note the following

Note. Replace seals and self-locking nuts.

Position exhaust manifold with catalytic converter seal and tighten nuts (Scheme 20)

Install right front wheel housing liner Description and Operation .

Install right catalytic converter RIGHT CATALYTIC CONVERTER

Install right front muffler FRONT MUFFLER .

Install plenum chamber bulkhead Description and Operation .

Install Heated Oxygen Sensor (HO2S) -G39- Removal and Installation .

Install noise insulation Description and Operation .

Proceed as follows

Remove left front muffler FRONT MUFFLER .

Remove Oxygen Sensor (O2S) behind Three Way Catalytic Converter (TWC) -G131- Removal and Installation .

Remove plenum chamber bulkhead Description and Operation .

Remove bolt -1- for power steering hydraulic fluid line bracket.

Scheme 33

Remove bolts -arrows- and subframe cross brace.

Remove nuts -arrows- and bolt -1- and left catalytic converter.

Scheme 34

Note. The installation location is shown with the engine removed.

1. Tightening specifications «MUFFLER ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007) .

Installation is in reverse order of removal, note the following

Note. Replace the seals and self-locking nuts.

Install subframe cross brace Removal and Installation .

Install plenum chamber bulkhead Description and Operation .

Install Oxygen Sensor (O2S) 2 behind Three Way Catalytic Converter (TWC) -G131- Removal and Installation .

Install left front muffler FRONT MUFFLER .

Proceed as follows

1. Transmission removed.

Remove electrical connector -1- for Oxygen Sensor (O2S) 2 behind Three Way Catalytic Converter (TWC) -G130- from bracket, disconnect it and free it up.

Scheme 35

Note. Ignore -2, 3 and 4- and -arrows-.

Remove right catalytic converter.

1. Tightening specifications «MUFFLER ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007) .

Installation is in reverse order of removal, note the following

Note. Replace seals and self-locking nuts.

Remove right front muffler FRONT MUFFLER .

Remove Oxygen Sensor (O2S) behind Three Way Catalytic Converter (TWC) -G130- Removal and Installation .

Remove plenum chamber bulkhead Description and Operation .

Remove bolt -1- for the power steering hydraulic fluid line bracket.

Remove bolts -arrows- and subframe cross brace.

Remove bolt -2-, press retaining tab off transmission and tilt it back -arrow-.

Scheme 36

Remove bolts -arrows- and bracket.

Remove nuts -arrows- and right catalytic converter.

Note. Ignore -1-.

1. Tightening specifications «MUFFLER ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007) .

Installation is in reverse order of removal, noting the following

Note. Replace the seals and self-locking nuts.

Install subframe cross brace Removal and Installation .

Install plenum chamber bulkhead Description and Operation .

Install Oxygen Sensor (O2S) 2 behind Three Way Catalytic Converter (TWC) -G130- Removal and Installation .

Install right front muffler FRONT MUFFLER .

Proceed as follows

Remove rear noise insulation by loosening fasteners -2, 3 and 4-.

Remove bolts -arrows- and front crossmember, if applicable.

Scheme 37

Remove left front muffler nuts -arrows-.

Scheme 38

Remove right front muffler nuts -arrows-.

Scheme 39

Loosen clamping sleeve -1- or -2-, slide it back and remove corresponding front muffler.

Scheme 40

1. Tightening specifications «MUFFLER ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007) .

Installation is in reverse order of removal, note the following

Note. Replace the seals and self-locking nuts.

Install exhaust system free of stress EXHAUST SYSTEM, INSTALLING .

Install front noise insulation Description and Operation .

Install rear noise insulation Description and Operation .

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 a depression around circumference of the exhaust pipe.

Special tools and workshop equipment required

1. Chain pipe cutter VAS 6254

Procedure

Proceed as follows

Separate exhaust pipes at a right angle at separating points -arrows- using chain pipe cutter VAS 6254.

Scheme 41

When installing, position clamping sleeves -arrows- on center of separating point

Scheme 42

Install double clamps so that the bolt ends do not project over lower edge of double clamp.

1. Installation position: Threaded connections point forward.

Install exhaust system free of stress EXHAUST SYSTEM, INSTALLING .

TAIL PIPE

Special tools and workshop equipment required

1. Chain pipe cutter VAS 6254

Procedure

Proceed as follows

1. Tightening specifications «MUFFLER ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007) .

Separate end pipe -1- at separating point -C- using chain pipe cutter VAS 6254.

Scheme 43

Connect end pipe -3- up to marking -A- so that slot on end pipe lines up with marking -B-.

Tighten clamping sleeve nut -2-.

EXHAUST SYSTEM, INSTALLING

Procedure

Proceed as follows

1. Align exhaust system when cold.
2. Tightening specifications «MUFFLER ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007) .

Vehicles Without Double Clamps Between Center and Rear Mufflers

Scheme 44

Loosen bolts on the front clamping sleeves.

Push exhaust system far enough forward -arrow- until preload on retaining loops in front of center muffler is -a- = 6 to 10 mm.

Tighten clamping sleeve threaded connections evenly.

Align tailpipes TAIL PIPES, ALIGNING .

Vehicles With Double Clamps Between Center and Rear Mufflers

Note. The center muffler also needs to be aligned on vehicles with clamping sleeves between the center and rear mufflers.

Loosen bolts on front and rear clamping sleeves.

Push exhaust system far enough forward -arrow- until preload on retaining loops in front of center muffler is -a- = 6 to 10 mm.

Tighten front clamping sleeve threaded connections evenly.

Push rear part of exhaust system far enough forward -arrow- so that the pre-tension at rear retaining loops of rear mufflers is -a- = 11 to 15 mm.

Align rear muffler horizontally.

Tighten rear clamping sleeve threaded connections evenly.

Align tailpipes TAIL PIPES, ALIGNING .

TAIL PIPES, ALIGNING

Procedure

Proceed as follows

1. Tightening specifications «MUFFLER ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-112007) .

Check distance of left and right tailpipes to bumper

Scheme 45

1. Dimension -x- left = dimension -x- right.

Correct dimension -x- as follows if necessary

Scheme 46

Loosen brace threaded connection -arrow- between exhaust pipes.

Adjust distance of rear mufflers to each other.

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 47

1. Chain pipe cutter VAS 6254

See also:
• Removal and Installation
• Removal and Installation
• LEFT ENGINE MOUNT
• Description and Operation
• Description and Operation
• Removal and Installation
• LEFT EXHAUST MANIFOLD
• EXHAUST SYSTEM, INSTALLING
• CENTER AND REAR MUFFLERS, SEPARATING
• TAIL PIPE
• TAIL PIPES, ALIGNING