Exhaust System - 4.2l v8 5v - Art, Awn, Bbd Audi S6 C5

WARNING!

1. DO NOT re-use fasteners that are worn or deformed in normal use.
2. Some fasteners are designed to be used only once and are unreliable and may fail the second time. This includes, but is not limited to nuts, bolts, washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with new parts where indicated and any other time when deemed necessary by inspection.

Note. After servicing the exhaust system, make sure that the system is not under stress and that there is sufficient clearance from body parts. If necessary, loosen the double clamps and align the muffler and exhaust pipes so that there is sufficient clearance to the body. The retaining rings must be evenly loaded. ALWAYS REPLACE self-locking nuts.

Exhaust system components, removing and installing

Note. Aligning exhaust system to relieve stress, see EXHAUST SYSTEM, ALIGNING TO RELIEVE STRESS Checking exhaust system for leaks, see EXHAUST SYSTEM, CHECKING FOR LEAKS Separating point between center and rear mufflers, see SEPARATING POINT BETWEEN CENTER AND REAR MUFFLERS Always replace gaskets and nuts.

Note. The following list refers to items in (Scheme 1).

1. 40 Nm (29 ft lb)
2. From Three Way Catalytic Converter (TWC)
3. Carriage bolt
4. Double clamp Tighten evenly to 40 Nm (29 ft lb) Installation position, see «DOUBLE CLAMPS FRONT, INSTALLATION POSITION»(/audi/s6/c5-1999-2004/remont/exhaust/#exhaust-system-42l-v8-5v-art-awn-bbd__double-clamps-front-installation-position) Always replace clamp after bolts have been loosened
5. 25 Nm (18 ft lb)
6. Mount With retainer
7. Center muffler
8. Repair double clamp Tighten evenly to 40 Nm (29 ft lb) Installation position, see «DOUBLE CLAMPS FRONT, INSTALLATION POSITION»(/audi/s6/c5-1999-2004/remont/exhaust/#exhaust-system-42l-v8-5v-art-awn-bbd__double-clamps-front-installation-position) Always replace clamp after bolts have been loosened
9. Separating point At the factory, center and rear mufflers are installed as single components. Replacement center and rear mufflers are supplied separately with double clamps for connecting the joints. Cutting at separating point, see «SEPARATING POINT BETWEEN CENTER AND REAR MUFFLERS»(/audi/s6/c5-1999-2004/remont/exhaust/#exhaust-system-42l-v8-5v-art-awn-bbd__separating-point-between-center-and-rear)
10. Rear muffler, right
11. Mount
12. Bracket
13. Rear muffler, left

Scheme 1

Separating point between center and rear mufflers

The cutting point between center an rear mufflers is used to replace parts separately if required.

1. Cut through connecting pipes between center and rear mufflers at points marked with groove: Dimension a = approx. 244 mm (9.6 in.)

Scheme 2

Removing

1. Remove engine. See «ENGINE, REMOVING AND INSTALLING»(ref-196260-S26726717202005100700000) .

For left exhaust manifold only

1. Remove guide tube for oil dipstick -arrow-.

Scheme 3

Both exhaust manifolds

1. Remove exhaust manifold -arrows-.

Scheme 4

Installing

Note. Replace self-locking nuts. Replace gaskets. Install new sealing ring on guide tube for dipstick.

1. Install in reverse sequence.

Tightening torques

TIGHTENING TORQUES: EXHAUST MANIFOLD

Front exhaust pipe with Three Way Catalytic (TWC) converter (left side), removing and installing

Note. Always replace seals, gaskets and self-locking nuts.

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

1. Remove engine cover panel -arrows-.
2. Remove cover above left cylinder head.
3. Remove air intake -arrows- between air cleaner and throttle body.
4. Disconnect connector -2- for oxygen sensor after Three Way Catalytic Converter (TWC) and move wiring aside.
5. Remove upper bolt between exhaust pipe and exhaust manifold.
6. Disconnect connector for oxygen sensor on left side -arrow- and move wiring aside.
7. From below loosen lower bolts -arrows- securing exhaust manifold to front exhaust pipe.
8. Remove exhaust pipe from retainer bracket -arrow-.
9. Loosen double clamp -1- and push toward front.
10. Carefully take out exhaust pipe.

Install in reverse order of removal but note the following

1. Align exhaust system to be free of stress. See «EXHAUST SYSTEM, ALIGNING TO RELIEVE STRESS»(/audi/s6/c5-1999-2004/remont/exhaust/#exhaust-system-42l-v8-5v-art-awn-bbd) .

TIGHTENING TORQUES: FRONT EXHAUST PIPES (LEFT SIDE)

Front exhaust pipe with catalytic converter, removing and installing (right side)

Note. Always replace seals, gaskets and self locking nuts.

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

1. Remove engine cover panel -arrows-.
2. Remove air intake duct -arrows- between air cleaner and throttle valve unit.
3. Disconnect connector -1- for oxygen sensor after Three Way Catalytic Converter (TWC) and move wiring aside.
4. Disconnect connector -3- for oxygen sensor and move wiring aside.
5. From above, remove bolt between exhaust pipe and exhaust manifold.
6. Remove right front road wheel.
7. From below, remove bolts -arrows- between exhaust pipe and exhaust manifold.
8. Remove exhaust pipe at retainer -arrow-.
9. Loosen double clamp -2- and push it forward.
10. Carefully remove exhaust pipe with catalytic converter.

Installation is in reverse order of removal but note the following

1. Align exhaust system to relieve stress. See «EXHAUST SYSTEM, ALIGNING TO RELIEVE STRESS»(/audi/s6/c5-1999-2004/remont/exhaust/#exhaust-system-42l-v8-5v-art-awn-bbd) .

TIGHTENING TORQUES: : FRONT EXHAUST PIPES (RIGHT SIDE)

Align exhaust system to avoid stress in the system and to prevent noise as follows

Note. Be sure muffler mountings are free of stress when installing. When aligning and relieving stress, loosen all bolted connections (except exhaust manifold), including mountings for catalytic converter. Align the exhaust system when cold. Perform the work in the order described below. Dimensions in the illustrations are approximate.

Vehicles without double clamp between center and rear mufflers

Note. The exhaust system must be cold when aligning.

Scheme 18

1. Loosen double clamp between catalytic converter and center muffler.
2. Push exhaust system far enough to the front until the gap (dimension -a-) between tail pipes -1- and rear bumper -2- is achieved

1. Dimension -a- = at least 40 mm (1.5 in.)

1. Tighten double clamps between catalytic converters and center mufflers evenly to 40 Nm (30 ft lb). Installation position => «DOUBLE CLAMPS FRONT, INSTALLATION POSITION»(/audi/s6/c5-1999-2004/remont/exhaust/#exhaust-system-42l-v8-5v-art-awn-bbd__double-clamps-front-installation-position) .

With correct distance between tail pipes/bumper, the rear mount is pre-tensioned to a = 7 to 11 mm (0.3 to .43 in.).

Scheme 19

Vehicles with double clamp between center and rear mufflers

Note. For vehicles with double clamps between center and rear muffles, the center muffler must also be aligned.

Scheme 20

Scheme 21

1. Loosen bolts of double clamps between catalytic converters and center mufflers.
2. Push exhaust pipes forward (in direction of arrow) untill pretension at left rear mount is at center muffler is a = 7 to 9 mm (0.3 to 0.4 in.).
3. Tighten double clamps between catalytic converters and center mufflers evenly to 40 Nm (30 ft lb). Installation position => «DOUBLE CLAMPS FRONT, INSTALLATION POSITION»(/audi/s6/c5-1999-2004/remont/exhaust/#exhaust-system-42l-v8-5v-art-awn-bbd__double-clamps-front-installation-position) .
4. Push rear muffler forward (in direction of arrow) until pretension at right rear mount at rear muffler is: Dimension a = 7 to 11 mm (0.3 to 0.43 in.)
5. Tighten double clamps between and center and rear mufflers evenly to 40 Nm (30 ft lb). Installation position, see «DOUBLE CLAMPS FRONT, INSTALLATION POSITION»(/audi/s6/c5-1999-2004/remont/exhaust/#exhaust-system-42l-v8-5v-art-awn-bbd__double-clamps-front-installation-position) .

Rear mufflers, aligning

With correct pre-tensioning of mountings, the gap between tail pipes -1- and bumper -2- is

1. Dimension -a- = at least 40 mm (1.5 in.)

Scheme 22

Double clamps front, installation position

The bolt ends must not protrude beyond lower end of clamp.

Scheme 23

Double clamps rear, installation position

The bolt ends must not protrude beyond lower end of clamp.

Scheme 24

Exhaust system, checking for leaks

1. Start engine and run at idle.
2. Plug tailpipes (with rag or cap) and leave plugged until check is complete.
3. Listen for noise at connecting points (cylinder head/exhaust manifold, exhaust manifold/front exhaust pipe, etc.) to locate any leaks.
4. Repair leaks found.

See also:
• EXHAUST SYSTEM, ALIGNING TO RELIEVE STRESS
• EXHAUST SYSTEM, CHECKING FOR LEAKS
• SEPARATING POINT BETWEEN CENTER AND REAR MUFFLERS
• DOUBLE CLAMPS FRONT, INSTALLATION POSITION