3.2l - Exhaust System, Emission Controls - Engine Code(s): Cala (coupe) (as of 12.2008) Audi A5 I

DESCRIPTION AND OPERATION

Version 2

Scheme 48

1. Bolt 23 Nm
2. Suspended Mount Replace if damaged Check pretension, refer to «EXHAUST SYSTEM, INSTALLING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008__exhaust-system-installing)
3. Center Muffler Original equipment as one unit with rear mufflers. For repairs, replace each separately. To remove in the A5 Cabriolet, remove the diagonal braces. (Scheme 53)Separating point, refer to «CENTER AND REAR MUFFLERS, SEPARATING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008__center-and-rear-mufflers-separating) Install exhaust system free of stress, refer to «EXHAUST SYSTEM, INSTALLING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008__exhaust-system-installing)
4. Rear muffler Original equipment as one unit with center muffler and tailpipe To remove in the A5 Cabriolet, remove the diagonal braces. (Scheme 53)In case of repairs, center muffler end muffler and tailpipe should be replaced individually Separating point between center and rear muffler, refer to «CENTER AND REAR MUFFLERS, SEPARATING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008__center-and-rear-mufflers-separating) Separating point between rear muffler and tailpipe, refer to «TAIL PIPE»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008__tail-pipe) Install exhaust system free of stress, refer to «EXHAUST SYSTEM, INSTALLING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008__exhaust-system-installing)
5. Gasket Replace
6. Nut 23 Nm
7. Catalytic Converter Protect from shocks and impact stress Removing and installing: Left for vehicles with manual transmissions. Refer to «LEFT CATALYTIC CONVERTER, MANUAL TRANSMISSION»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008). Left for vehicles with the multitronic 0AW or automatic transmission 0B6. Refer to «LEFT CATALYTIC CONVERTER, MULTITRONIC OR AUTOMATIC TRANSMISSION»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008). Right for vehicles with manual transmissions or multitronic 0AW. Refer to «RIGHT CATALYTIC CONVERTER, MANUAL OR MULTITRONIC TRANSMISSION»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008). Right for vehicles with automatic transmission 0B6. Refer to «RIGHT CATALYTIC CONVERTER, AUTOMATIC TRANSMISSION»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008). Individual components of suspension (Scheme 51)
8. Nut 23 Nm
9. Gasket Replace
10. Front Muffler With decoupling element, do not bend the decoupling element more than 10° or it could be damaged Removing and installing, refer to «FRONT MUFFLER»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) Install exhaust system free of stress, refer to «EXHAUST SYSTEM, INSTALLING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008__exhaust-system-installing)
11. Front Clamping Sleeve Installed location (Scheme 49) Before tightening, align exhaust system tension-free, refer to «EXHAUST SYSTEM, INSTALLING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008__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, refer to «TAIL PIPE»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008__tail-pipe) Aligning, refer to «END PIPES, ALIGNING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008__end-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-122008__exhaust-system-installing)
17. Nut Replace 20 Nm
18. Rear Clamping Sleeve For individual replacement of center and rear mufflers Installed location (Scheme 49)Before tightening, align exhaust system tension-free, refer to «EXHAUST SYSTEM, INSTALLING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008__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, refer to «EXHAUST SYSTEM, INSTALLING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008__exhaust-system-installing)

Scheme 49

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 50

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 51

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

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

Scheme 52

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

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

Scheme 53

To remove, remove the diagonal braces for the center and rear mufflers -1- and -2-.

Install diagonal braces.

Scheme 54

1. Nut Replace Grease with hot bolt paste; Hot bolt paste, Tightening specifications and sequence, refer to: Left (Scheme 55), right (Scheme 56)
2. Bracket for heat shield
3. Exhaust Manifold Removing and installing, refer to: Left «LEFT EXHAUST MANIFOLD»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008), right «RIGHT EXHAUST MANIFOLD»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008)
4. Gasket Replace
5. Heat shield
6. Bolt 10 Nm
7. Oxygen sensor Before catalytic converter Removing and installing, refer to «Removal and Installation»(/audi/a5/i-2007-2011/remont/fuel-system/#32l-multiport-fuel-injection-engine-codes-cala-coupe)
8. Catalytic converter Assembly overview, refer to «MUFFLER OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008)
9. Nut Replace Grease with hot bolt paste; Hot bolt paste, 23 Nm
10. Gasket Replace

Scheme 55

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

Scheme 56

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

Scheme 57

1. Nut 9 Nm
2. Bonded Rubber Bushing
3. Secondary Air Injection (AIR) Pump Motor -V101- Removing and installing, refer to «SECONDARY AIR INJECTION PUMP -V101»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) Attach the connector to the bracket Checking in "Guided Functions"
4. O-rings Replace
5. Secondary Air Hose
6. Retaining Clip
7. O-ring Replace
8. Gasket Replace
9. Bolts 9 Nm
10. Right Secondary Air Injection (AIR) Combination Valve Checking, refer to «AIR COMBINATION VALVES - VERSION 1, CHECKING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) Removing and installing, refer to «RIGHT SECONDARY AIR INJECTION COMBINATION VALVE»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008)
11. Bolt 9 Nm
12. Secondary Air Hose
13. Bolt 9 Nm
14. Left Secondary Air Injection (AIR) Combination Valve Checking, refer to «AIR COMBINATION VALVES - VERSION 1, CHECKING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) Removing and installing, refer to «LEFT SECONDARY AIR INJECTION COMBINATION VALVE»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008)
15. Bolts 9 Nm
16. Gasket Replace
17. Bolt 9 Nm
18. Bracket For secondary air injection hose
19. O-ring Replace
20. Secondary Air Hose
21. Bracket For Secondary Air Injection (AIR) pump motor -V101
22. Bolt 9 Nm

Scheme 58

Tighten the heat shield bolts -arrows- -1- to 9 Nm.

Scheme 59

1. Nut 9 Nm
2. Bonded Rubber Bushing
3. Secondary Air Injection (AIR) Pump Motor -V101- Removing and installing, refer to «SECONDARY AIR INJECTION PUMP»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) Attach the connector to the bracket Checking in "Guided Functions"
4. O-rings Replace
5. Secondary Air Hose
6. Retaining Clip
7. O-ring Replace
8. Gasket Replace
9. Bolts 9 Nm
10. Vacuum Hose
11. Right Secondary Air Injection (AIR) Combination Valve Checking, refer to «AIR COMBINATION VALVES - VERSION 2, CHECKING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008__air-combination-valves-version-2) Removing and installing, refer to «SECONDARY AIR INJECTION RIGHT COMBINATION VALVE»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008)
12. Bolt 9 Nm
13. AIR Sensor 1 -G609- Removing and installing, refer to «FUEL LEVEL SENSOR 1»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008)
14. O-ring Replace
15. Secondary air hose
16. Bolt 9 Nm
17. Left AIR combination valve Checking, refer to «AIR COMBINATION VALVES - VERSION 2, CHECKING»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008__air-combination-valves-version-2) Removing and installing, refer to «SECONDARY AIR INJECTION LEFT COMBINATION VALVE»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008)
18. Vacuum Hose
19. Screws 9 Nm
20. Gasket Replace
21. Bolt 9 Nm
22. Bracket For secondary air injection hose
23. O-ring Replace
24. Secondary Air Hose
25. Bracket For AIR pump motor -V101
26. Bolt 9 Nm

Tighten the heat shield bolts -arrows- -1- to 9 Nm.

FASTENER TIGHTENING SPECIFICATIONS

Catalytic Converter Mounting Components, Manual or Automatic Transmission

v

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

Catalytic Converter Mounting Elements, Multitronic Transmission

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

LEFT EXHAUST MANIFOLD, TIGHTENING SPECIFICATIONS AND SEQUENCE

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

RIGHT EXHAUST MANIFOLD, TIGHTENING SPECIFICATIONS AND SEQUENCE

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

EXHAUST SYSTEM, CHECKING FOR LEAKS

Start the engine and let it run at idle.

Seal the exhaust pipes with cloths or plugs during the 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.

PROCEDURE

1. Hose connections properly sealed.

Remove plenum chamber bulkhead. Refer to Description and Operation .

Right Secondary Air Injection (AIR) Combi-Valve

Free up the fuel line -1- and the wire -2- to the EVAP canister at the air guide pipe.

Scheme 60

Remove vacuum hose -3- from the connection on the air guide pipe.

Remove the air guide pipe by loosening the hose clamp -4- and opening the clips -arrows-.

Continued for Both Sides

Remove the bolts -2- and push the secondary air hoses to the side.

Scheme 61

Note. Ignore -1-.

Connect hose -arrow- to the secondary air combination valve as illustrated.

Scheme 62

Blow lightly into the assisting hose by mouth, do not use compressed air.

1. Secondary Air Injection (AIR) combination valve must be closed, it must not be possible to blow through.

Blow forcefully into the assisting hose by mouth, do not use compressed air.

1. The Secondary Air Injection (AIR) combination valve must open, it must be possible to blow through.

If the switch point cannot be detected, replace secondary air injection (AIR) combi-valve. Refer to: Left LEFT SECONDARY AIR INJECTION COMBINATION VALVE , right RIGHT SECONDARY AIR INJECTION COMBINATION VALVE .

ASSEMBLING

Assembly is in reverse order of removal, note the following

Note. The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps appropriate for the model. In order to be able to securely mount the air guide hoses on their connectors, spray the bolts on the previously used clamps with a rust remover.

Install the plenum chamber bulkhead. Refer to Description and Operation .

AIR COMBINATION VALVES - VERSION 2, CHECKING

Special tools and workshop equipment required

1. Hand Vacuum Pump VAS 6213

1. Vacuum lines and hose connections free of leaks.
2. Vacuum lines not plugged.

Remove engine covers -arrows-.

Scheme 63

Remove the left and right vacuum hoses -1 and 2- on the combination valve being checked.

Scheme 64

Connect the VAS 6213 to the vacuum hose for the combination valve to be checked.

Remove the front secondary air hose -arrow- from its bracket and disconnect it; to do so press the release buttons.

Scheme 65

Blow into the Secondary Air Injection (AIR) hose using light pressure (do not use pressurized air).

1. Secondary Air Injection (AIR) combination valves must be closed, it must not be possible to blow through.

Operate hand vacuum pump.

1. The relevant combination valve must open, it must not be possible to blow through

If the secondary air combination valve does not open, replace. Refer to: Left SECONDARY AIR INJECTION LEFT COMBINATION VALVE , right SECONDARY AIR INJECTION RIGHT COMBINATION VALVE .

Assembly is in reverse order of removal, note the following

Note. Replace O-ring.

REMOVING

Remove left front muffler. Refer to FRONT MUFFLER .

Remove Oxygen Sensor (O2S) 2 after catalytic converter -G131- -2-. Refer to Removal and Installation .

Scheme 66

All A4, A5 Coupe

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

Scheme 67

Remove the bolts -arrows- and the subframe crossbrace.

Note. The illustration shows the installation location on a vehicle with dynamic steering.

A5 Cabriolet

Remove left and right bolts -2-.

Scheme 68

Note. Ignore -1-.

Remove bolt -2- for the power steering hydraulic fluid line bracket.

Scheme 69

Remove bolts -1- and -arrows- and the subframe crossbrace.

All Vehicles

Remove bolts -arrows- and the left drive axle heat shield -1-, if applicable.

Scheme 70

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

Scheme 71

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

INSTALLING

1. Tightening specifications. Refer to «MUFFLER OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) .

Installation is in reverse order of removal, note the following

Note. Replace the seals and self-locking nuts.

Install subframe crossbrace. Refer to Removal and Installation .

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

Install left front muffler. Refer to FRONT MUFFLER .

1. Transmission removed.

Remove the electrical connector -1- for the Oxygen Sensor (O2S) 2 after catalytic converter -G131- from the bracket and disconnect it.

Scheme 72

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

Remove nuts -arrows- and the left catalytic converter.

Note. The installation location is shown with the engine removed. Ignore -1-.

1. Tightening specifications. Refer to «MUFFLER OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) .

Installation is in reverse order of removal, note the following

Note. Replace the seals and self-locking nuts.

1. Transmission removed.

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

Scheme 73

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

Remove right catalytic converter.

1. Tightening specifications. Refer to «MUFFLER OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) .

Installation is in reverse order of removal, note the following

Note. Replace the seals and self-locking nuts.

Remove right front muffler. Refer to FRONT MUFFLER .

Remove Oxygen Sensor after Three Way Catalytic Converter (TWC) -G130- -2-. Refer to Removal and Installation .

Scheme 74

All A4, A5 Coupe

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

Remove bolts -arrows- and the subframe crossbrace.

Note. The illustration shows the installation location on a vehicle with dynamic steering.

A5 Cabriolet

Remove left and right bolts -1 and 2- and the brace.

Remove bolt -2- for the power steering hydraulic fluid line bracket.

Remove bolts -1- and -arrows- and the subframe crossbrace.

All Vehicles

Remove bolts -arrows- and the right drive axle heat shield -1-, if applicable.

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

Scheme 75

Remove bolts -arrows- and the bracket.

Remove nuts -arrows- and the right catalytic converter.

Scheme 76

Note. Ignore -1-.

1. Tightening specifications. Refer to «MUFFLER OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) .

Installation is in reverse order of removal, note the following

Note. Replace the seals and self-locking nuts.

Install subframe crossbrace. Refer to Removal and Installation .

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

Install the right front muffler. Refer to FRONT MUFFLER .

Remove rear noise insulation -2-. Refer to Description and Operation .

Scheme 77

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

Scheme 78

Remove left front muffler nuts -arrows-.

Scheme 79

Remove right front muffler nuts -arrows-.

Scheme 80

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

Scheme 81

1. Tightening specifications. Refer to «MUFFLER OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) .

Installation is in reverse order of removal, note the following

Note. Replace the seals and self-locking nuts.

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

Install front crossmember. Refer to Removal and Installation .

Install rear noise insulation. Refer to 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 the circumference of the exhaust pipe.

Special tools and workshop equipment required

1. Chain Pipe Cutter VAS 6254

Procedure

Separate the exhaust pipes at a right angle at the separating points -arrows- using the VAS 6254.

Scheme 82

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

Scheme 83

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. Refer to EXHAUST SYSTEM, INSTALLING .

TAIL PIPE

Special tools and workshop equipment required

1. Chain Pipe Cutter VAS 6254

Procedure

1. Tightening specifications. Refer to «MUFFLER OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) .

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

Scheme 84

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

1. Align exhaust system when cold.
2. Tightening specifications. Refer to «MUFFLER OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) .

Vehicles without double clamps between center and rear mufflers

Loosen the bolts on the front clamping sleeves.

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

Scheme 85

Tighten clamping sleeve threaded connections evenly.

Align tailpipes. Refer to END 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 the bolts on the front and rear clamping sleeves.

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

Tighten the 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 the rear clamping sleeve threaded connections evenly.

Align tailpipes. Refer to END PIPES, ALIGNING .

END PIPES, ALIGNING

Procedure

1. Tightening specifications. Refer to «MUFFLER OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) .

Check distance of left and right tailpipes to bumper

Scheme 86

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

Correct dimension -x- as follows if necessary

Scheme 87

Loosen the brace threaded connection -arrow- between the exhaust pipes.

Adjust the distance of the rear mufflers to each other.

Remove plenum chamber bulkhead. Refer to Description and Operation .

Remove Heated Oxygen Sensor (HO2S) 2 -G108- -1-. Refer to Removal and Installation .

Remove left engine mount. Refer to LEFT ENGINE MOUNT

Remove left front muffler. Refer to FRONT MUFFLER .

Remove nuts -arrows- and bolt -1-.

Remove the left catalytic converter from the exhaust manifold and lay it aside.

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

Remove bolts -arrows- and the left engine support.

Scheme 88

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

Scheme 89

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

Scheme 90

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

Installation is in reverse order of removal, note the following

Note. Replace the seal and self-locking nuts.

Position the exhaust manifold with the catalytic converter seal and tighten the nuts (Scheme 55)

Install engine supports with the left engine mount. Refer to LEFT ENGINE MOUNT .

Install HO2S 2 --. Refer to Removal and Installation .

Install left catalytic converter: For vehicles with manual transmissions. Refer to LEFT CATALYTIC CONVERTER, MANUAL TRANSMISSION . For vehicles with the multitronic 0AW or automatic transmission 0B6, refer to LEFT CATALYTIC CONVERTER, MULTITRONIC OR AUTOMATIC TRANSMISSION .

Install left front muffler. Refer to FRONT MUFFLER .

Install noise insulation. Refer to Description and Operation .

Install plenum chamber bulkhead. Refer to Description and Operation .

Remove noise insulation -1 and 2-. Refer to Description and Operation .

Remove Heated Oxygen Sensor (HO2S) -G39- -1-. Refer to Removal and Installation .

Remove plenum chamber bulkhead. Refer to Description and Operation .

Remove right front muffler. Refer to FRONT MUFFLER .

Remove nuts -arrows- and bolt -1- and move the catalytic converter to the rear.

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

Remove right front wheel.

Remove right front wheel housing liner. Refer to Description and Operation .

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

Scheme 91

Note. Ignore -arrows-.

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

Scheme 92

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

Scheme 93

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

Installation is in reverse order of removal, note the following

Note. Replace the seals and self-locking nuts.

Position exhaust manifold with the catalytic converter seal and tighten the nuts. (Scheme 56)

Install right catalytic converter: For vehicles with manual transmissions or the Multitronic 0AW. Refer to RIGHT CATALYTIC CONVERTER, MANUAL OR MULTITRONIC TRANSMISSION . For vehicles with the automatic transmission 0B6. Refer to RIGHT CATALYTIC CONVERTER, AUTOMATIC TRANSMISSION .

Install plenum chamber bulkhead. Refer to Description and Operation .

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

Install noise insulation. Refer to Description and Operation .

Mount front wheel. Refer to General Information .

Note. During installation, all cable ties must be re-installed at the same location.

Remove left front muffler. Refer to FRONT MUFFLER .

Remove plenum chamber bulkhead. Refer to Description and Operation .

Remove electrical connector -arrow- for the Oxygen Sensor (O2S) 2 after catalytic converter -G131- from the bracket, disconnect it and lay it aside.

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

Remove nuts -arrows- and bolt -1- and remove the left catalytic converter from the exhaust manifold and move it to the back.

Remove bolts -arrows- and heat shield -1-.

Remove bolts -1 and 2- and left secondary air combination valve.

1. Tightening specifications. Refer to «AIR SYSTEM - VERSION 1 OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008), (Scheme 58).

Installation is in reverse order of removal, note the following

Note. Replace the gasket.

Install left catalytic converter: For vehicles with manual transmissions. Refer to LEFT CATALYTIC CONVERTER, MANUAL TRANSMISSION . For vehicles with the multitronic 0AW or automatic transmission 0B6. Refer to LEFT CATALYTIC CONVERTER, MULTITRONIC OR AUTOMATIC TRANSMISSION .

Install plenum chamber bulkhead. Refer to Description and Operation .

Remove right front muffler. Refer to FRONT MUFFLER .

Remove plenum chamber bulkhead. Refer to Description and Operation .

Free up the fuel hose -1- and the Evaporative Emission (EVAP) canister hose -2- on the air duct pipe.

Remove vacuum hose -3- from the connection on the air guide pipe.

Remove the air guide pipe by loosening the hose clamp -4- and opening the clips -arrows-.

Remove the electrical connector -1- for the Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- from the bracket and disconnect it.

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

Remove nuts -arrows- and bolt -1- and remove the right catalytic converter from the exhaust manifold and move it to the back.

Remove bolts -arrows- and heat shield -1-.

Scheme 94

Remove bolts -2-.

Scheme 95

Remove right secondary air combination valve and remove the bolts -1- for the secondary air hose.

1. Tightening specifications. Refer to «AIR SYSTEM - VERSION 1 OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008), (Scheme 58).

Installation is in reverse order of removal, note the following

Note. Replace the gasket. The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps appropriate for the model. In order to be able to securely mount the air guide hoses on their connectors, spray the bolts on the previously used clamps with a rust remover.

Install the right catalytic converter: For vehicles with manual transmissions or the Multitronic 0AW. Refer to RIGHT CATALYTIC CONVERTER, MANUAL OR MULTITRONIC TRANSMISSION . For vehicles with the automatic transmission 0B6. Refer to RIGHT CATALYTIC CONVERTER, AUTOMATIC TRANSMISSION .

Install plenum chamber bulkhead. Refer to Description and Operation .

Note. During installation, all cable ties must be re-installed at the same location.

Remove front noise insulation -1-. Refer to Description and Operation .

Disconnect electrical connector -3- on the Secondary Air Injection (AIR) pump motor --.

Scheme 96

Disconnect hoses -1- and -2- for the secondary air injection (AIR).

Note. The installation location is shown with the wheel housing lining removed.

Remove bolts -1 and 2- and remove the bumper cover end panel toward the rear.

Scheme 97

Release the clamps -A arrows- and remove the air intake grille -1- at the left and right from the lower section of the bumper cover -arrow B-.

Scheme 98

Remove bolts -arrows- and remove the secondary air pump.

Scheme 99

Note. The installation location is shown with the bumper cover removed.

1. Tightening specifications. Refer to «AIR SYSTEM - VERSION 1 OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) .

Installation is in reverse order of removal, note the following

Note. Replace O-rings.

Install bumper cover end panel. Refer to Removal and Installation .

Install noise insulation. Refer to Description and Operation .

Note. During installation, all cable ties must be re-installed at the same location.

Remove left front muffler. Refer to FRONT MUFFLER .

Remove plenum chamber bulkhead. Refer to Description and Operation .

Remove electrical connector -arrow- for the Oxygen Sensor (O2S) 2 after catalytic converter -G131- from the bracket, disconnect it and lay it aside.

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

Remove nuts -arrows- and bolt -1- and remove the left catalytic converter from the exhaust manifold and move it to the back.

Remove bolts -arrows- and heat shield -1-.

Remove bolts -3- for the secondary air hose.

Scheme 100

Remove vacuum line -2- from the secondary air injection (AIR) combination valve.

Remove bolts -1- and remove secondary air injection (AIR) combi-valve.

1. Tightening specifications. Refer to «AIR SYSTEM - VERSION 2 OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008), see scheme 13

Installation is in reverse order of removal, note the following

Note. Replace the gasket.

Install left catalytic converter. Refer to LEFT CATALYTIC CONVERTER, MULTITRONIC OR AUTOMATIC TRANSMISSION .

Install plenum chamber bulkhead. Refer to Description and Operation .

Remove right front muffler. Refer to FRONT MUFFLER .

Remove plenum chamber bulkhead. Refer to Description and Operation .

Free up the fuel hose -1- and EVAP canister hose -2- on the air duct pipe.

Remove vacuum hose -3- from the connection on the air guide pipe.

Remove the air guide pipe by loosening the hose clamp -4- and opening the clips -arrows-.

Remove electrical connector -1- for the Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- from the bracket and disconnect it.

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

Remove nuts -arrows- and bolts -1- and remove the right catalytic converter from the exhaust manifold and move it to the back.

Remove bolts -arrows- and heat shield -1-.

Remove the vacuum line -2- from the secondary air injection (AIR) combination valve.

Scheme 101

Remove bolts -3-, remove the right secondary air combination valve and remove the bolts -1- for the secondary air hose.

1. Tightening specifications. Refer to «AIR SYSTEM - VERSION 2 OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008), see scheme 13.

Installation is in reverse order of removal, note the following

Note. Replace the gasket. The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps appropriate for the model. In order to be able to securely mount the air guide hoses on their connectors, spray the bolts on the previously used clamps with a rust remover.

Install right catalytic converter. Refer to RIGHT CATALYTIC CONVERTER, AUTOMATIC TRANSMISSION

Install plenum chamber bulkhead. Refer to Description and Operation .

Note. During installation, all cable ties must be re-installed at the same location.

Remove front noise insulation -1-. Refer to Description and Operation .

Disconnect electrical connector -3- on the Secondary Air Injection (AIR) pump motor -V101-.

Disconnect hoses -1 and 2- for the Secondary Air Injection (AIR).

Note. The installation location is shown with the wheel housing lining removed.

Remove bolts -1 and 2- and remove the bumper cover end panel toward the rear.

Release clamps -A arrows- and remove the air intake grille -1- at the left and right from the lower section of the bumper cover -arrow B-.

Remove bolts -arrows- and remove the secondary air pump.

Note. The installation location is shown with the bumper cover removed.

1. Tightening specifications. Refer to «AIR SYSTEM - VERSION 2 OVERVIEW»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) .

Installation is in reverse order of removal, note the following

Note. Replace O-rings.

Install bumper cover end panel. Refer to Removal and Installation .

Install noise insulation. Refer to Description and Operation .

Remove rear engine cover -top arrows-.

Free up the fuel hose -1- and the Evaporative Emission (EVAP) canister hose -2- on the air duct pipe.

Remove vacuum hose -3- from the connection on the air guide pipe.

Remove air guide pipe by loosening the hose clamp -4- and opening the clips -arrows-.

Disconnect electrical connector -1-.

Scheme 102

Open the locking mechanisms -arrows- and Secondary Air Injection Sensor 1 -G609- -2-.

Installation is in reverse order of removal, note the following

Note. Replace O-ring. The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps appropriate for the model. In order to be able to securely mount the air guide hoses on their connectors, spray the screws on the previously used clamps with a rust remover.

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 103

Scheme 104

1. Hand Vacuum Pump VAS 6213
2. Chain Pipe Cutter VAS 6254

See also:
• Removal and Installation
• Description and Operation
• Removal and Installation
• Description and Operation
• LEFT ENGINE MOUNT
• General Information
• Removal and Installation
• EXHAUST SYSTEM, INSTALLING
• CENTER AND REAR MUFFLERS, SEPARATING
• TAIL PIPE
• LEFT CATALYTIC CONVERTER, MANUAL TRANSMISSION
• END PIPES, ALIGNING
• AIR COMBINATION VALVES - VERSION 2, CHECKING