Work Procedure
Work Procedure:1 Preparatory work
1.1 Remove trim panel for /engine compartment cover --> Workshop Manual '700819 Removing and installing trim panel for hood compartment/engine compartment lid - section on "Removing"'.
1.2 Drive the vehicle onto a lifting platform and raise it --> Workshop Manual '400000 Lifting the vehicle'.
CAUTION
Hot components
^ Risk of burns
--> Let hot components cool down.
--> Wear personal protective gear.
1.3 Remove tailpipe --> Workshop Manual '263419 Removing and installing tailpipe - section on "Removing"'.
1.4 Remove the two rear mufflers --> Workshop Manual '263319 Removing and installing rear silencer - section on "Removing" '.
1.5 Open spot welds on clamps on the tailpipe using a chisel or parting grinder --> Figure 4. Remove clamps on tailpipe.
2 Install rear mufflers for sport exhaust system --> Workshop Manual '263319 Removing and installing rear silencer - section on "Installing"'
2.1 Position two new seals on the studs on the flange of the two catalytic converters.
2.2 Loosely profit the new right rear muffler on the right catalytic converter using three new M8 hexagon nuts --> Figure 5.
2.3 Fit new clamp (--> Figure 6 -A-) and tailpipe (--> Figure 6 -B-) loosely on the right rear muffler using a new clip (--> Figure 6 -C-).
2.4 Loosely pre-fit the new left rear muffler on the left catalytic converter using three new M8 hexagon nuts.
2.5 Fit tailpipe and clamp on the left rear silencer and align the two rear mufflers --> Figure 7. Tighten M8 hexagon nuts on the flange between the two rear mufflers and the catalytic converter.
Tightening torque 23 Nm (17 ft.lb.)
2.6 Secure the two rear mufflers on the rear muffler holder with four new M8 x 16 hexagon-head bolts (--> Figure 8-A-) and four new M8 hexagon nuts (--> Figure 8-B-).
Tightening torque 23 Nm (17 ft.lb.)
2.7 Secure the two rear mufflers on the rear muffler holder using a corrugated clip and a new M8 x 40 hexagon-head bolt on each one --> Figure 9.
Tightening torque 23 Nm (17 ft.lb.)
2.8 Slide tailpipe cover onto the tailpipe, align it according to instructions in the Workshop Manual and secure it.
Tightening torque 65 Nm (48 ftlb.)
3 Fit electric changeover valve
3.1 Unclip standard changeover valve, which is clipped in on the intake distributor between cylinders 1 and 2 --> Figure 10 -arrow-.
Pull changeover valve off the bent protective tube and replace bent protective tube with a Y-piece (3-way distributing piece --> Figure 11 -arrow-).
3.2 Prepare electric changeover valve for installation
3.2.1 Attach and align bent protective tube (1 tube supplied --> Figure 12
-A1- and 1 tube from the standard changeover valve --> Figure 12
-A2-) to the connections for the electric changeover valve --> Figure 12 -A3- as shown in --> Figure 12 -B-.
3.2.2 Clip holder --> Figure 12 -A4- into electric changeover valve --> Figure 12 -A3- as shown in --> Figure 12 -C-.
3.3 Screw on changeover valve --> Figure 13 -B1- with holder fitted --> Figure 12
-A4- and M6 x 16 bolt --> Figure 13 -B3- on engine suspension support --> Figure 13-A, arrow/B2- by hand.
Tilt change-over valve and holder forward by approx. 45° in direction of travel to prevent chafing on the engine compartment cover when the connector is fitted!
Tightening torque 9.7 Nm (7.5 ft.lb.)
CAUTION
Risk of damage to lines and/or hoses (vacuum)
^ due to incorrect routing.
--> Maintain a sufficient distance from components exposed to high temperatures while driving.
--> Avoid making tight bends.
4 Route vacuum lines for activating exhaust flaps
Connection diagram for vacuum lines
4.1 Fit hose clip for vacuum lines.
4.1.1 Clip hose clip (999.651.286.01, --> Figure 2, item H) onto a cooling fin on the transmission.
- Manual transmission: in direction of travel going right --> Figure 15
- Tiptronic transmission: in direction of travel going left --> Figure 16
4.1.2 Fit hose clip in rear muffler area.
Information
The description provided here is only for the right side. The installation procedure is the same for the left side.
Clip in hose clip (2 ea. --> Figure 2, item G) on rear muffler holder --> Figure 17-A-.
Clip in hose clip (2 ea. --> Figure 2, item F) on the strut for the mufflers --> Figure 17-B-.
4.2 Route and connect vacuum lines.
4.2.1 Insert Tekalan line (supplied) approx. 10 mm into the free Y-piece connection (standard change-over valve) and route it to the electric change-over valve as follows:
Y-piece connection for electric change-over valve --> underneath intake distributor --> bent protective tube on underside of electric change-over valve --> Figure 18 -A-).
4.2.2 Clip change-over valve back in on the intake distributor between cylinders 1 and 2.
4.2.3 Slide Tekalan line approx. 10 mm into the second bent protective tube, at the side of the change-over valve at the engine support (--> Figure 18-B-) and route it as follows:
Second bent protective tube (--> Figure 18-B-) --> above transmission --> clip for cooling fin on transmission --> Y-piece (above transmission) --> to the rear-muffler vacuum units
4.2.4 Fix Tekalan lines in place on existing components using tie-wraps if necessary (see --> Figure 18-C-).
4.2.5 Separate remaining Tekalan line in the middle and slide it at least 10 mm into the two free ends of the Y-piece.
CAUTION
Risk of damage to lines and/or hoses (vacuum)
^ due to incorrect routing.
--> Maintain a sufficient distance from components exposed to high temperatures while driving.
--> Avoid making tight bends.
4.2.6 Fit the two Tekalan lines into the steel-encased line for each rear muffler and tighten hose clamps (left side on vehicle with Tiptronic transmission --> Figure 19-inset-).
4.2.7 Clip steel-encased lines into clip on strut (2 ea. --> Figure 19-A-) and rear muffler holder (2 ea. --> Figure 19 -B-).
5 Connect electric changeover valve
5.1 Expose connector (2-pin) on engine wire harness (--> Figure 20-A, arrow-) and route it to connection for electric changeover valve.
5.2 Pull off dummy connector and connect 2-pin plug connection --> Figure 20 -B-.
5.3 Fix plug connection in place again without tensile stress and so that it cannot be chafed or jolted.
6 ONLY for vehicles without Sport Chrono package (I-nos. 639/640):
Install sport exhaust system button and route and connect electric wire harness
6.1 Preparatory work
6.1.1 Move cabrio top to service position --> Workshop Manual '6101 IN Hood service position'.
6.1.2 Disconnect and cover the battery, then connect the power supply while the vehicle is in the workshop Technical In formation '270600 Battery: Battery care and maintenance/power supply'.
6.1.3 Remove engine compartment lid --> Workshop Manual '700819 Removing and installing trim panel for hood compartment/engine compartment lid - section on "Removing"'.
6.1.4 Remove carpet lining at the sides of the luggage compartment and rear wall --> Workshop Manual '700619 Removing and installing rear luggage compartment trim (carpet lining) section on "Removing"'.
6.1.5 Expose DME control unit --> Workshop Manual '247019 Removing and installing DME control unit - section on "Removing"'.
6.1.6 Remove left side trim panel --> Workshop Manual '707519 Removing and installing side trim panel - section on "Removing"'.
6.1.7 Remove inner door sill trim at the left --> Workshop Manual '680519 Removing and installing inner door sill trim - section on "Removing"'
6.1.8 Remove switch console in center console area --> Workshop Manual '962719 Removing and installing switch console - section on "Removing".
6.2 Connect electric wire harness for sports exhaust system button to the DME control unit
D - Connector D, DME control unit
A - Connector A, button module for sports exhaust system
6.2.1 Pull off connector Don DME control unit --> Figure 22 -D-.
6.2.2 Release secondary lock on connector housing D --> Figure 23-A, arrows - and pull both connectors out of the housing --> Figure 23-B, arrow-.
6.2.3 Insert line 2386; GY/GN; 0.5sq. into connector D; chamber 17 (sport exhaust system).
6.2.4 Insert line 2385; BU; 0.5sq. into connector D; chamber 6 (sport exhaust system).
6.2.5 Fit connector in connector housing D and connect all plug connections to the DME control unit.
6.3 Guide Tekalan hose or wire spindle on the left side wall, out of the rear luggage compartment (--> Figure 24-A-), under the water drip pan in the wiring duct to the left B-pillar (--> Figure 24-B-).
Connect electric wire harness to the end pointing to the rear luggage compartment.
6.4 Route electric wire harness for sport exhaust system button.
6.4.1 DME control unit --> along wire harness at the vehicle side --> left side wall --> under water drip pan --> cable duct --> B-pillar (between insulating mat and body)
6.4.2 B-pillar --> left door sill --> along
wiring duct to A-Pillar --> Figure 25.
6.4.3 A-Pillar --> underneath switch panel --> installation posit)on of button trim --> Figure 26.
6.5 Connect electric wire harness to sport exhaust system button
6.5.1 Open secondary lock on 16-pin connector.
6.5.2 Plug socket contacts of lines (Nos. 2386 and 2385) into 16-pin plug socket as follows:
Line 2386; GY/GN; 0.5 sq. --> chamber All (button LED):
Line 2385; BU; 0.5 sq. --> chamber A10 (button signal).
6.5.3 Close secondary lock on 16-in connector.
6.6 Use tie-wraps or wrapping tape to secure electric wire harness to existing lines or components without tension and so that no chafing occurs.
6.7 Concluding work for installing button for sport exhaust system
6.7.1 Install switch console in center console area --> Workshop Manual '962719 Removing and installing switch console - section on "Installing"'.
6.7.2 Install inner door sill trim at the left --> Workshop Manual '680519 Removing and installing inner door sill trim - section on "Installing".
6.7.3 Install left side trim panel --> Workshop Manual '707519 Removing and installing side trim panel - section on "Installing".
6.7.4 Install DME control unit --> Workshop Manual '247019 Removing and installing DME control unit - section on "Installing".
6.7.5 Install carpet lining at the sides of the luggage compartment and rear wall --> Workshop Manual '700619 Removing and installing rear luggage compartment trim (carpet lining) - section on "Installing".
6.7.6 Install engine compartment lid --> Workshop Manual '700819 Removing and installing trim panel for hood compartment/engine compartment lid - section on "Installing"'.
6.7.7 Connect the battery and connect the power supply while the vehicle is in the workshop --> Technical Information '270600 Battery: Battery care and maintenance/power supply'.
6.7.8 Move cabrio top out of service position and close it --> Workshop Manual '6101IN Hood service position'.
7 Concluding work and function test
7.1 Read out the fault memory of all control units, correct any existing faults, and erase the fault memory.
7.2 Configure Required/Actual installed components list for gateway.
7.2.1 Select "GATEWAY coding" in the menu and continue with [>>].
7.2.2 Select "Required installed components lists" and continue with [>>].
7.2.3 Select "Sound exhaust system" and continue with [>>].
7.2.4 The menu item "Sound exhaust system not installed" is highlighted. Select "Sound exhaust system - installed" and press [F8] to write coding.
7.2.5 Press [<<] to return to the higher-level menu items and check that the coding was completed successfully.
7.3 Disconnect PIWIS Tester P 9718 and the battery charger if necessary.
7.4 Carry out a function test on the "sports exhaust system".
7.4.1 Start the vehicle.
Depending on the vehicle status, the "sport exhaust system" is activated for 2 to 3 seconds because there is no vacuum at the rear mufflers. The exhaust flaps are open and the sound of the exhaust motor can be heard clearly.
As the vacuum at the rear mufflers increases, the exhaust flaps close and the sound of the exhaust motor eases off. The "sport exhaust system" is not active. The diode in the "Sport" or "Twin tailpipe" button does not light up when you start the vehicle!
7.4.2 Press the "Sport" or "Twin tailpipe" button.
After a regulating phase of around 2 to 3 seconds, the exhaust flaps open and the sound of the exhaust motor can be heard clearly. The "sport exhaust system" is active!
The diode in both buttons ("Sport" and "Twin tailpipe") lights up!
The correct function of the sport exhaust system can also be checked at any time by getting a second person to perform a visual inspection of the regulating movement (linkage at the exhaust flaps).
7.5 Malfunction: Diode lights up continuously in the "Twin tailpipe" button. Only concerns vehicles manufactured before 12 December 2006.
7.5.1 Check PIWIS Tester data status. This must be version 17.10 at least.
7.5.2 It not, install new data version on the PIWIS Tester.
7.5.3 Copy new data records for the relevant vehicle model to the vehicle control unit.
7.5.4 Re-configure the system as described in Step 7.2 and repeat the function test as described in Step 7.4.