Front Exhaust Pipe With Catalytic Converter, Removing and Installing
Front Exhaust Pipe With Catalytic Converter, Removing And Installing
Special tools, testers and auxiliary items required
- Hex ball socket 3247
- Ring spanner 7-piece set for oxygen sensor 3337
- Torque wrench V.A.G 1331
Removing
- Exhaust system must not be hotter than lukewarm.
CAUTION:
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
- Route all the various lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum lines and hoses) and electrical wiring so that the original positions are restored.
- Ensure sufficient clearance to all moving or hot components.
NOTE: All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.
- Check whether a coded radio is installed. If necessary, obtain radio anti-theft coding.
- Switch off ignition and all electrical consumers.
- Disconnect battery Ground (GND) strap.
- Remove intake manifold cover.
- Unbolt coolant expansion tank and move it toward front with hoses connected.
- Disconnect hose between intake air scoop and Mass Air Flow (MAF) sensor at MAF sensor.
- Disconnect electrical connectors for intake manifold change-over valve and Secondary Air Injection (AIR) valve.
- Pull off vacuum lines -1- and -2-.
- Remove bolts and nuts - arrows -.
- Move mounting plate for intake manifold change-over valve and for Secondary Air Injection (AIR) valve toward front.
- Remove intake air scoop with connection hose.
- On vehicles with oxygen sensors behind catalytic converter, separate oxygen sensor connectors (green and brown) at bulkhead and expose wiring up to transmission.
- Disconnect harness connector for oxygen sensor before catalytic converter cylinder head bank 1 (right side) / cylinder head bank 2 (left side) and expose wire (corresponding to the exhaust pipe to be removed).
NOTE: Note allocation of cable ties.
- Remove oxygen sensor before catalytic converter at right or left side.
- Remove left and right axle shaft shielding plates - arrows -. Third bolt is not visible in illustration.
Vehicles with manual transmission
- On vehicles with oxygen sensors behind catalytic converter, expose wires for oxygen sensors behind catalytic converter at transmission and disconnect both wires.
NOTE: Note location of cable ties.
- Unbolt right/left exhaust pipe from exhaust manifold and from transmission support.
- Loosen right / left double clamp between exhaust pipe and center muffler and slide toward rear.
- Guide out front exhaust pipe with right / left catalytic converter toward rear.
Vehicles with automatic transmission
- For vehicles with All Wheel Drive secure driveshaft with alignment fixture 3213 and unfasten intermediate bearing from vehicle floor.
NOTE: During this work procedure, the driveshaft must not be separated from the transmission.
- Unscrew upper nut from right / left exhaust manifold (corresponding to exhaust pipe to be removed).
- Support transmission.
- Remove rear bolts -1 and - 2 of subframe on both sides of vehicle.
- Lower transmission slightly.
- On vehicles with oxygen sensors behind catalytic converter, expose wires for oxygen sensors behind catalytic converter at transmission and disconnect both wires.
NOTE: Note location of cable ties.
- Unbolt right/left exhaust pipe from exhaust manifold and from transmission support.
- Loosen right/left double clamp between exhaust pipe and center muffler and slide toward rear.
- Unbolt transmission support -1 with transmission mount - 2 at right/left.
NOTE:
- A second technician is required.
- To remove the lower bolt for the transmission support, raise the transmission slightly and use hex ball socket 3247.
- To remove the upper bolt of the transmission support, lower the transmission slightly and swing the exhaust pipe as far upward as possible.
- Guide out front exhaust pipe with right / left catalytic converter toward rear.
Installing
CAUTION:
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
- Route all the various lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum lines and hoses) and electrical wiring so that the original positions are restored.
- Ensure sufficient clearance to all moving or hot components.
Installation is performed in reverse order. Note the following:
Vehicles with automatic transmission
- Install transmission support and transmission mount.
- Fasten subframe to body, See Suspension, Wheels, Steering
For vehicles with All Wheel Drive:
- Fasten intermediate bearing of driveshaft to vehicle floor. Afterward, remove alignment fixture 3213 and tighten bolts using specified torque.
Continued for all vehicles
- Secure oxygen sensor lines according to routing before removal.
- Install front exhaust pipe with catalytic converter and oxygen sensors.
- Install axle shaft shielding plates.
- Install holding plate for intake manifold change-over valve.
- Install intake air scoop.
- Check Diagnostic Trouble Code (DTC) memory of all control modules, repair all stored malfunctions, and erase DTC memory afterward Vehicle Diagnosis, Testing and Information System VAS 5051; Guided Fault Finding; Vehicle System Test, or Vehicle Diagnosis and Service Information System VAS 5052; On Board Diagnostic (OBD).
- Perform road test and check DTC memory of all control modules again.
NOTE: Observe safety precautions that apply to road tests.