Left
Left Exhaust Pipe With Catalytic Converter, Removing And Installing
NOTE: Next, removal and installation for vehicles with automatic transmission is described.
Special tools and equipment
- engine/transmission hoist
- 3337 ring spanner, 7-piece set
- Locking compound G 052 112 A3
Removing
- Remove rear engine cover (arrows).
- Remove cover -1- in engine compartment (right side).
- Remove bolts for holding plate -3- for solenoid valves (arrows).
- Disconnect intake air hose -1- at Mass Air Flow (MAF) sensor.
- Disconnect hose -4- from air guide -2-
- Remove bolt (arrow) and disconnect air guide -2- at throttle valve control module.
- Disconnect hose -1- from air guide if installed.
NOTE: Illustration depicts air guide with the removed engine from rear.
- Remove cover -1- in engine compartment (left side).
- Remove coolant reservoir (arrows).
- Disconnect electrical wiring to Engine Coolant Level (ECL) Warning Switch -F66- at bottom of expansion tank.
- Tie coolant expansion tank with connected coolant hoses -1 to 3- to side.
- Disconnect vacuum hose to brake booster (arrows).
- Remove heat shield for harness connectors at left of bulkhead.
- Remove harness connectors -1 to 4- from bracket at left of bulkhead.
- Disconnect electrical harness connectors -1- and -4-.
- Guide wires to the oxygen sensors downward.
Vehicles with automatic transmission 01J:
- Unscrew oxygen sensor behind catalytic converter (arrow) using special tool 3337.
All:
- Remove nut -2- for left exhaust pipe/exhaust manifold which is accessible from top.
NOTE: Illustration is shown with engine removed.
- Remove left front wheel.
- For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater at noise insulation.
- Loosen mounting parts -1 to 4- and remove noise insulation.
- Remove heat shield -1- for left drive axle.
NOTE: Flex joint in front exhaust pipe must not be bent more than 10°, otherwise it may be damaged.
- Disconnect exhaust system at left double clamp (left arrow).
- Remove heat shield above exhaust system.
- Remove heat shield for drive shaft (arrows).
- Remove bolts at flange of transmission/drive shaft.
- Push drive shaft to rear final drive together. The constant velocity joints can be adjusted axially.
- Rest drive shaft on exhaust system.
- Remove VAG1359/2 universal mount from VAG1383A engine/gearbox jack and place a piece of wood -1- onto punch instead.
- Support transmission using VAG1383A engine/transmission lift.
NOTE: For automatic transmission 01 V, position engine/transmission lift directly behind the ATF pan. Insert a wood block to protect the transmission housing. Never lift at the ATF pan!
WARNING!
The lock carrier must be installed.
- First remove bolts -2- and -3- and then mounting bolts -1- and -4- of subframe.
- Slowly lower transmission and subframe using VAG1383A engine/gearbox jack.
- Remove bracket for front exhaust pipe (arrow).
- Slightly lift transmission using VAG1383A engine/transmission lift.
- Remove bolts -1 to 4- for transmission mount.
- Unbolt both transmission mounts -5- and -6- at transmission housing and remove transmission supports with transmission mounts.
- Slowly lower transmission again.
- Expose oxygen sensor wires.
- Remove nuts -1- and -3- for front exhaust pipe/exhaust manifold which are accessible from bottom.
NOTE: Illustration is shown with engine removed.
- Remove front exhaust pipe with catalytic converter.
Installing
Installation is reverse of removal, noting the following:
NOTE:
- All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
- Replace gaskets and self-locking nuts.
- Install transmission mounts and supports.
- Install subframe:
- Installing drive shaft:
- Align exhaust system tension-free.
NOTE:
- Individual parts of the exhaust hangers at transmission for vehicles with front wheel drive.
- Individual parts of the exhaust hangers at transmission for vehicles with all wheel drive.
- Oxygen sensor threads are coated with an assembly paste. This paste must not contact sensor openings.
- Cable of oxygen sensor must always be secured in the same position when installing so that contact with the exhaust pipe is avoided.
Tightening torques
Component Nm
Front exhaust pipe with catalytic converter
to exhaust manifold 27
Front exhaust pipe with catalytic converter
to hanging strap 25
Drive axle protection to transmission 23
Oxygen sensor to catalytic converter 55