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2.0l - Exhaust System, Emission Controls - Engine Code(s): Cdma (coupe) Audi TT 8J рестайлинг

Exhaust 20 illustrations ~940 words

EXHAUST MANIFOLD

The exhaust manifold and turbocharger are one unit. Removing and installing, refer to TURBOCHARGER .

Scheme 34

Scheme 34: MUFFLER OVERVIEW
Scheme 34: MUFFLER OVERVIEW
  1. Retaining Loop Replace if damaged
  2. Nut 23 Nm
  3. Bracket for Exhaust System
  4. Bolt 23 Nm
  5. Bolt 23 Nm
  6. Suspended Mount Replace if damaged
  7. Tunnel Brace
  8. Gasket Replace
  9. Nut Replace 40 Nm Coat the threaded pin with hot bolt paste; hot bolt paste
  10. Heated Oxygen Sensor -G39- Removing and installing, refer to «Removal and Installation»(/audi/tt/8j-2010-2014/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-coupe__removal-and-installation)
  11. Front Exhaust Pipe with catalytic Converter and Front Muffler With decoupling element, decoupling element must not be bent 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-2010-2014/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cdma-coupe__front-exhaust-pipe-with-catalytic-converters) Remove decoupling element guard on replacement part as late as possible Install exhaust system free of stress, refer to «EXHAUST SYSTEM, INSTALLING»(/audi/tt/8j-2010-2014/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cdma-coupe__exhaust-system-installing)
  12. Heated Oxygen Sensor 2 -G108- Removing and installing, refer to «Removal and Installation»(/audi/tt/8j-2010-2014/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-coupe__removal-and-installation)
  13. Clamping Sleeve Before tightening, align exhaust system tension-free, refer to «EXHAUST SYSTEM, INSTALLING»(/audi/tt/8j-2010-2014/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cdma-coupe__exhaust-system-installing) Installed position (Scheme 35)Tighten threaded connections evenly.
  14. Nut 23 Nm
  15. Bracket
  16. Retaining Loops Replace if damaged
  17. Bracket
  18. Exhaust Door Valve -N220- With vacuum reservoir Check the exhaust flap vacuum diaphragm, refer to «EXHAUST FLAP VACUUM DIAPHRAGM, CHECKING»(/audi/tt/8j-2010-2014/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cdma-coupe__exhaust-flap-vacuum-diaphragm-checking)
  19. Nut 23 Nm
  20. Bolt 23 Nm
  21. Rear Muffler Unit with center muffler Install exhaust system free of stress, refer to «EXHAUST SYSTEM, INSTALLING»(/audi/tt/8j-2010-2014/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cdma-coupe__exhaust-system-installing)
  22. Nut 23 Nm
  23. Bolt 23 Nm

Scheme 35

Scheme 35
Scheme 35

Install clamping sleeve in angle position shown.

  1. α = approximately 20°
  2. The threaded connections are toward the right.
  3. The nuts are toward the top.

END PIPES, ALIGNING

Procedure

Align rear muffler so there is an even distance between bumper openings and tailpipes.

Scheme 36

Scheme 36: END PIPES, ALIGNING
Scheme 36: END PIPES, ALIGNING
  1. Left dimension -a- = right dimension -a-.
  2. Dimension -b- = approximately 19 mm
  3. Dimension -c- = approximately 22.5 mm.

To align tailpipes, loosen rear muffler mounts.

  1. Tightening specifications, refer to «MUFFLER OVERVIEW»(/audi/tt/8j-2010-2014/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cdma-coupe) .

FASTENER TIGHTENING SPECIFICATIONS

ComponentBolt SizeNm
Bracket for Exhaust System, Nut23
Bracket for Rear Muffler, Bolt/Nut23
Clamping Sleeve, Nut23
Exhaust Door Valve, Bolt/Nut23
Front Exhaust Pipe with catalytic Converter and Front Muffler 1, 240
Suspended Mount23
Tunnel Brace23
1 Coat the threaded pin with hot bolt paste 2 Replace

EXHAUST SYSTEM, CHECKING FOR LEAKS

Procedure

Start the engine and let it run in idle.

Seal the exhaust pipes with cloths or plugs during the leak test.

Check the connections between the cylinder head and exhaust manifold with the turbocharger, exhaust manifold with turbocharger and front exhaust pipe, etc. by listening for leaks.

Repair detected leaks.

EXHAUST FLAP VACUUM DIAPHRAGM, CHECKING

Special tools and workshop equipment required

  1. Hand Vacuum Pump VAS 6213

Procedure

Remove the hose from the exhaust flap vacuum diaphragm on the rear muffler.

Connect the VAS 6213 at the vacuum diaphragm.

Scheme 37

Scheme 37
Scheme 37

Operate hand vacuum pump.

Scheme 38

Scheme 38
Scheme 38
  1. Linkage must move upward.

Vent hand vacuum pump.

  1. Linkage must move downward.

If the linkage does not move, make sure it is not stuck and check the vacuum diaphragm for leaks.

FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS AND FRONT MUFFLER

Removing

Scheme 39

Scheme 39: FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS AND FRONT MUFFLER
Scheme 39: FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS AND FRONT MUFFLER

Remove the heated oxygen sensor -G39-. Refer to Removal and Installation .

Remove the engine cover -arrows-.

Scheme 40

Scheme 40
Scheme 40

Remove the bolts -arrows- and air guide.

Remove the coolant hose by loosening the hose clamp -1-.

Scheme 41

Scheme 41
Scheme 41

Disconnect the connector -2- from the Mass Airflow (MAF) Sensor -G70-.

Detach upper section of air filter housing -arrow- and remove air filter insert.

Remove the bolts -arrows- and the lower section of the air filter housing.

Scheme 42

Scheme 42
Scheme 42

Remove bolt -arrow-.

Scheme 43

Scheme 43
Scheme 43

Loosen the hose clamp -1- and lay the air guide pipe aside with the hose -2- connected.

Note. Ignore -3-.

Remove the bolts -arrows- and nuts -1- and then remove the heat shield.

Scheme 44

Scheme 44
Scheme 44

Remove the nuts -arrows- on the front exhaust pipe/turbocharger connection from the top.

Scheme 45

Scheme 45
Scheme 45

Note. The illustration shows the installation position from below.

Mark position of flexible disc to bevel box flange for reinstallation.

Remove driveshaft flexible disc from bevel box -arrows- while counter holding on triangle flange with lever.

Scheme 46

Scheme 46
Scheme 46
CAUTIONThe shaft seal -arrow- in the driveshaft flange could be damaged. Press driveshaft horizontally as far back and to right side of vehicle as possible.

Scheme 47

Scheme 47
Scheme 47

Remove bolts -1- and -2- under the vehicle floor.

Scheme 48

Scheme 48
Scheme 48

Remove the cover from the oxygen sensor electrical connector bracket.

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

Remove the electrical connector -arrow- from the oxygen sensor after three way catalytic converter -G130- from the bracket and disconnect it.

Scheme 49

Scheme 49
Scheme 49

Remove the bolts -arrows-, exhaust system bracket and tunnel brace.

Scheme 50

Scheme 50
Scheme 50
CAUTIONRisk of damaging decoupling elements. Do not bend decoupling element in front exhaust pipe more than 10°.

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

Scheme 51

Scheme 51
Scheme 51

Remove the front exhaust pipe with the catalytic converter and front muffler.

Installing

  1. For the correct tightening specifications, refer to «MUFFLER OVERVIEW»(/audi/tt/8j-2010-2014/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cdma-coupe) .

Installation is performed in reverse order of removal, noting the following.

Note. Replace seals and self-locking nuts. The hose supports, 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.

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

EXHAUST SYSTEM, INSTALLING

Procedure

  1. Align exhaust system when cold.
  2. Tightening specifications, refer to «MUFFLER OVERVIEW»(/audi/tt/8j-2010-2014/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cdma-coupe) .

Loosen the clamping sleeve threaded connections.

Press the rear muffler as far forward as possible -arrow- until the tension at the left retaining loop -a- = 11 to 13 mm.

Scheme 52

Scheme 52
Scheme 52

Install clamping sleeve in angle position shown.

  1. α = approximately 20°.
  2. The threaded connections are toward the right.
  3. The nuts are toward the top.

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 53

Scheme 53: SPECIAL TOOLS
Scheme 53: SPECIAL TOOLS
  1. Hand Vacuum Pump VAS 6213

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