Right Front Exhaust Pipe With Primary and Main Catalytic Converter, Removing and Installing

Right front exhaust pipe with primary and main catalytic converter, removing and installing

Special tools and equipment





^ 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).





- 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.





- Detach 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 right of bulkhead.
- Disconnect connectors -1 -and -2-.
- Move wires clear of Heated Oxygen Sensor (H02S).





- Unfasten quick-release fasteners -1- to -3- and remove noise insulation (2 sections).





- Remove heat shield -1- for right drive shaft and differential (2 sections).





- Remove heat shield fasteners (arrow) at longitudinal member.

Note: Engine transmission assembly has been removed in illustration.

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 down drive shaft 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 right 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- of front exhaust pipe/exhaust manifold bolted joint evenly and in stages and align front exhaust pipe with lug.
- Install subframe.
- Install 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