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2.0l - Exhaust System, Emission Controls - Engine Code(s): Bpy (coupe) (as of 10.2010) Audi TT 8J

Exhaust 12 illustrations ~872 words

EXHAUST SYSTEM OVERVIEW

Note. Flex joint in front exhaust pipe must not be bent by more than 10°, otherwise it may be damaged. 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 clamping sleeve and align muffler and exhaust pipe so that there is adequate distance to body and that weight is evenly distributed among the suspended mounts. The exhaust manifold and turbocharger are one component, removing and installing, refer to TURBOCHARGER .

Scheme 37

Scheme 37: EXHAUST SYSTEM OVERVIEW
Scheme 37: EXHAUST SYSTEM OVERVIEW
  1. Bolt 23 Nm
  2. Bracket for Exhaust System
  3. Clamping Sleeve Before tightening, ensure exhaust system is tension-free, refer to «EXHAUST SYSTEM, ALIGNING»(/audi/tt/8j-2006-2010/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-bpy-coupe-as-of-102010__exhaust-system-aligning) Installed location (Scheme 38)Tighten bolts evenly
  4. Nut 20 Nm
  5. Bracket for Exhaust System
  6. Retaining Loop Replace if damaged
  7. Bolt 23 Nm
  8. Suspended Mount Replace if damaged
  9. Bolt 23 Nm
  10. Tunnel Brace
  11. Gasket Replace
  12. Nut Replace 40 Nm Coat turbocharger stud bolts with hot bolt paste. Hot bolt paste.
  13. Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19- 55 Nm Only use hot bolt paste to grease thread; do not let paste get onto slits of oxygen sensor body Hot bolt paste. Removing and installing, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-coupe__removal-and-installation)
  14. Front Exhaust Pipe with Catalytic Converters and Front Muffler Flex joint must not be bent by more than 10° - otherwise it may be damaged Do not load decoupling element on cable Do not damage wire mesh at decoupling element Protect catalytic converter from shocks and impact stress Removing and installing, refer to «FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS AND FRONT MUFFLER»(/audi/tt/8j-2006-2010/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-bpy-coupe-as-of-102010__front-exhaust-pipe-with-catalytic-converters) Install exhaust system free of stress, refer to «EXHAUST SYSTEM, ALIGNING»(/audi/tt/8j-2006-2010/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-bpy-coupe-as-of-102010__exhaust-system-aligning)
  15. Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and Heater for Oxygen Sensor 1 after Catalytic Converter -Z29- 55 Nm Only use hot bolt paste to grease thread; do not let paste get onto slits of oxygen sensor body Hot bolt paste. Removing and installing, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-coupe__removal-and-installation)
  16. Rear Muffler Install exhaust system free of stress, refer to «EXHAUST SYSTEM, ALIGNING»(/audi/tt/8j-2006-2010/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-bpy-coupe-as-of-102010__exhaust-system-aligning)
  17. Retaining Loop Replace if damaged
  18. Nut 23 Nm

Scheme 38

Scheme 38
Scheme 38

Install clamping sleeve in angled position shown.

  1. Threaded connections point toward the right.
  2. Nuts face up.
  3. α = approximately 20°

EXHAUST SYSTEM, ALIGNING

  1. Align exhaust system when cold.
  1. For the correct tightening specifications, refer to «EXHAUST SYSTEM OVERVIEW»(/audi/tt/8j-2006-2010/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-bpy-coupe-as-of-102010__exhaust-system-overview)

Loosen front double clamping bolts EXHAUST SYSTEM OVERVIEW .

Scheme 39

Scheme 39
Scheme 39

Press rear muffler forward -arrow- until pretension at left retaining loop -a- = 11 to 13 mm.

Install clamping sleeve in angled position shown.

  1. Threaded connections point toward the right.
  2. Nuts face up.
  3. α = approximately 20°

Tighten clamping sleeve threaded connections evenly.

Aligning Tailpipe

Align tailpipes so that the clearance -a- on the left is the same as the clearance -a- on the right.

Scheme 40

Scheme 40
Scheme 40

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

  1. Dimension b = min. 21 mm

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

FASTENER TIGHTENING SPECIFICATIONS

ComponentBolt SizeNm
Bracket for Exhaust System, Bolt/Nut (1)23
Bracket for Exhaust System, Nut (2)20
Front Exhaust Pipe with Catalytic Converters and Front Muffler, Nut (3) , (4)40
Oxygen Sensor (5)55
Suspended Mount23
Tunnel Brace23
(1) For bolt tightening clarification, refer to EXHAUST SYSTEM OVERVIEW and see item -2- (2) For bolt tightening clarification, refer to EXHAUST SYSTEM OVERVIEW and see items -5- (3) Always replace (4) Coat turbocharger stud bolts with hot bolt paste (5) Use hot bolt paste to grease threads
(1)For bolt tightening clarification, refer to EXHAUST SYSTEM OVERVIEW and see item -2
(2)For bolt tightening clarification, refer to EXHAUST SYSTEM OVERVIEW and see items -5
(3)Always replace
(4)Coat turbocharger stud bolts with hot bolt paste
(5)Use hot bolt paste to grease threads

EXHAUST SYSTEM, CHECKING FOR LEAKS

Start engine and run at idle speed.

Seal tailpipe with cloths or plug for the duration of the leak test.

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

Repair detected leaks.

FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS AND FRONT MUFFLER

Special tools and workshop equipment required

  1. Ring Spanner 7-Piece Set 3337

Removing

Disconnect the electrical connector on the mass air flow (MAF) sensor -G70- -3-.

Scheme 41

Scheme 41
Scheme 41

Open clips -1 and 2- and remove air guide hose from MAF sensor.

Remove front air intake connector on lock carrier -4-.

Remove engine cover.

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

Scheme 42

Scheme 42
Scheme 42

Remove heated oxygen sensor -arrow- using a tool from the 3337.

Scheme 43

Scheme 43
Scheme 43

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

Scheme 44

Scheme 44
Scheme 44

Remove nuts -1- and -2- on oxygen sensor electrical connector bracket under vehicle floor and remove cover.

Scheme 45

Scheme 45
Scheme 45

Remove bolt -3- and free up electrical wiring to oxygen sensor.

Remove connector coupling from bracket -arrow-.

Scheme 46

Scheme 46
Scheme 46

Disconnect electrical connector to oxygen sensor (O2S) after three way catalytic converter (TWC) -G130-.

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

Remove exhaust system bracket and tunnel brace -arrows-.

Scheme 47

Scheme 47
Scheme 47

Note. Do not bend the flex joint in the front exhaust pipe more than 10° or it could be damaged.

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

Remove front exhaust pipe with catalytic converter and front muffler.

Installing

Install in reverse order of removal. Note the following

  1. For the correct tightening specifications, refer to «EXHAUST SYSTEM OVERVIEW»(/audi/tt/8j-2006-2010/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-bpy-coupe-as-of-102010__exhaust-system-overview)

Note. Replace gaskets and self-locking nuts.

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

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 48

Scheme 48: SPECIAL TOOLS
Scheme 48: SPECIAL TOOLS
  1. Ring Spanner 7-Piece Set 3337

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