EXHAUST MANIFOLD
The exhaust manifold and turbocharger are one unit. Removing and installing, refer to TURBOCHARGER .
Scheme 119
- Retaining Loop Replace if damaged
- Nut 23 Nm
- Bracket for Exhaust System
- Bolt 23 Nm
- Bolt 23 Nm
- Suspended Mount Replace if damaged
- Tunnel Brace
- Gasket Replace
- Nut Replace 40 Nm Coat the threaded pin with hot bolt paste; hot bolt paste
- 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-roadster__removal-and-installation)
- 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-roadster__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-roadster__exhaust-system-installing)
- 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-roadster__removal-and-installation)
- 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-roadster__exhaust-system-installing) Installed position (Scheme 120)Tighten threaded connections evenly.
- Nut 23 Nm
- Bracket
- Retaining Loops Replace if damaged
- Bracket
- 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-roadster__exhaust-flap-vacuum-diaphragm-checking)
- Nut 23 Nm
- Bolt 23 Nm
- 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-roadster__exhaust-system-installing)
- Nut 23 Nm
- Bolt 23 Nm
Scheme 120
Install clamping sleeve in angle position shown.
- α = approximately 20°
- The threaded connections are toward the right.
- 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 121
- Left dimension -a- = right dimension -a-.
- Dimension -b- = approximately 19 mm
- Dimension -c- = approximately 22.5 mm.
To align tailpipes, loosen rear muffler mounts.
- Tightening specifications, refer to «MUFFLER OVERVIEW»(/audi/tt/8j-2010-2014/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cdma-roadster) .
FASTENER TIGHTENING SPECIFICATIONS
| Component | Bolt Size | Nm |
|---|---|---|
| Bracket for Exhaust System, Nut | 23 | |
| Bracket for Rear Muffler, Bolt/Nut | 23 | |
| Clamping Sleeve, Nut | 23 | |
| Exhaust Door Valve, Bolt/Nut | 23 | |
| Front Exhaust Pipe with catalytic Converter and Front Muffler 1, 2 | 40 | |
| Suspended Mount | 23 | |
| Tunnel Brace | 23 | |
| 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
- 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 122
Operate hand vacuum pump.
Scheme 123
- Linkage must move upward.
Vent hand vacuum pump.
- 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 124
Remove the heated oxygen sensor -G39-. Refer to Removal and Installation .
Remove the engine cover -arrows-.
Scheme 125
Remove the bolts -arrows- and air guide.
Remove the coolant hose by loosening the hose clamp -1-.
Scheme 126
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 127
Remove bolt -arrow-.
Scheme 128
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 129
Remove the nuts -arrows- on the front exhaust pipe/turbocharger connection from the top.
Scheme 130
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 131
| CAUTION | The 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 132
Remove bolts -1- and -2- under the vehicle floor.
Scheme 133
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 134
Remove the bolts -arrows-, exhaust system bracket and tunnel brace.
Scheme 135
| CAUTION | Risk 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 136
Remove the front exhaust pipe with the catalytic converter and front muffler.
Installing
- For the correct tightening specifications, refer to «MUFFLER OVERVIEW»(/audi/tt/8j-2010-2014/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cdma-roadster) .
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
- Align exhaust system when cold.
- Tightening specifications, refer to «MUFFLER OVERVIEW»(/audi/tt/8j-2010-2014/remont/exhaust/#20l-exhaust-system-emission-controls-engine-codes-cdma-roadster) .
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 137
Install clamping sleeve in angle position shown.
- α = approximately 20°.
- The threaded connections are toward the right.
- The nuts are toward the top.
SPECIAL TOOLS
Special tools and workshop equipment required
Scheme 138
- Hand Vacuum Pump VAS 6213
Edition 3 17 2011