Left Front Exhaust Pipe With Primary and Main Catalytic Converter, Removing and Installing
Left front exhaust pipe with primary and main catalytic converter, removing and installing
Special tools and equipment
^ Hose clamps 3094
^ Engine/transmission jack V.A.G 1383 A
Removing
Note: All cable ties unfastened or cut open on removal are to be re-attached in same position on installation.
- Remove rear engine cover (arrows).
- Pinch off coolant hose -1- with hose clamp 3094 and remove at coolant expansion tank.
- Remove bolts (arrows) and coolant expansion tank -2-.
- Disconnect wire to engine coolant level (ECL) warning switch -F66-at bottom of expansion tank and lay aside coolant expansion tank with coolant hose -3- connected.
- If necessary, use suitable plug to seal connection.
- Remove secondary air system pipe at left combination valve (arrow) and lay pipe aside.
Note: Engine has been removed in illustration.
- Remove crankcase breather hose (arrow) at intake manifold.
- Remove air cleaner cover -2-.
- Remove air duct -1
Note: Pull out clips (arrows) using pry lever 80-200.
- Disconnect connector -3- at evaporative emission (EVAP) canister purge regulator valve -N80- item -2-.
- Detach solenoid valve from holder.
- Disconnect connector -4- at mass air flow sensor.
- Turn hose -1= to secondary air pump counter-clockwise and detach.
- Remove air hose -5- at mass air flow sensor.
- Remove bolt (arrow).
- Remove air cleaner housing with mass air flow sensor.
- Remove air hose from throttle valve control module (arrow).
- Disconnect air hose (arrow) to secondary air system combination valves.
- Take connectors -1= to -4- out of holder on left of bulkhead.
- Disconnect connectors -1 -and -4-.
- Move wires clear of Heated Oxygen Sensor (HO2S).
- Remove nut -2- (accessible from above) of front exhaust pipe manifold.
Note: Engine has been removed in illustration.
- Unfasten quick-release fasteners -1- to -3- and remove noise insulation (2 sections).
- Remove heat shield -1- for left drive shaft.
- Remove left drive shaft:
WARNING: Wheel bearing must not be subject to load when loosening off collared bolt for drive shaft (vehicle must not be standing on its wheels).
Note: To avoid damage, de-coupling element in front exhaust pipe is never to be kinked by more than 10°.
- Separate exhaust system at clamps -1- and -2-.
- Remove two heat shields (arrows).
- Remove heat shield for transmission (arrows).
- Remove heat shield -A- for drive shaft (arrows).
- Remove bolts at transmission/drive shaft flange.
- Retract drive shaft to rear final drive. Constant velocity joints are axially adjustable.
- Set drive shaft down on exhaust system.
Note: Never raise transmission from oil pan.
- Place engine/transmission jack VAG 1383 A press tool behind ATF oil pan at location marked by (arrow) and support transmission.
Note: Lock carrier must be in position.
- First remove bolts -2- and -3- and then bolts -1- and -4- of subframe.
- Use engine/transmission jack VAG 1383 A to slowly lower transmission and subframe.
- Remove bolt (arrow) at lug for left front exhaust pipe.
- Move Heated Oxygen Sensor (H02S) wires aside.
- Remove nuts -1- and -3- (accessible from underneath) for front exhaust pipe exhaust manifold.
Note: Engine has been removed in illustration.
- Take out front exhaust pipe with primary and main catalytic converter.
Installing
Install in reverse order, note the following:
Note:
^ Replace gaskets and se/Mocking nuts.
^ Re-attach aft cable ties at same location on installation.
^ Secure aft hose connections with standard hose clamps; Refer to Part Supplier
- Tighten nuts -1- to -3- on front exhaust pipe exhaust manifold bolted joint evenly and in stages and align front exhaust pipe with lug.
- Install subframe.
- Install drive shaft.
- Install left drive shaft.
Note: For individual components of exhaust system mounting at transmission, Refer to Exhaust System, Service and Repair, Exhaust System Components, Removing and Installing, see Fig. 4.
- Perform stress-free alignment of exhaust system.
Tightening torques