Exhaust Pipe with Catalytic Converter

Exhaust Pipe with Catalytic Converter

• The catalytic converters are removed "downward". The transfer case support and driveshaft must be removed for this purpose.

Special tools, testers and auxiliary items required

• Engine-/Gearbox Jack (V.A.G 1383 A)

• Gearbox Support (T10337)

Removing

- On a vehicle with a air suspension, activate the vehicle lift mode.

- Remove the connecting pipe - arrows -.






- Remove the upper air filter housing.

- Disconnect the connector - 1 - from the throttle valve control module.






- Remove the bolts - arrows - and remove the throttle valve control module.

- Remove the vacuum lines from the intake manifold as follows:






1 For the Evaporative Emission (EVAP) canister, press release buttons
3 For the brake booster

• Ignore - item 2 - and the - arrow -.

- Remove the intake manifold support bolts - arrow - from the intake manifold.






- Remove the bolts - 1 and 2 - and remove the intake manifold support/heat shield.

- Remove the oxygen sensors. Refer to => [ Oxygen Sensors ] Oxygen Sensors.

- Remove the exhaust pipe with catalytic converter to exhaust manifold nuts - arrows -.






- Remove the bolts - arrows - for catalytic converter exhaust bank 1.






- Remove the noise insulation.






- Remove the noise insulation bracket bolts - arrows - and bracket.






- Remove the bracket - A -.






- Loosen the clamps - arrows -. Remove the suspended mount - 1 and 2 - bolts.






- Support the transmission using the engine-/gearbox jack (V.A.G 1383 A) and the installed gearbox support (T10337) as shown in the illustration.






- Remove the transfer case carrier bolts - 1 and 2 -.






- Remove the bolts - arrows - and remove the transfer case bracket.






• Ignore - items 1 and 2 -.

- Remove the front driveshaft.

- Remove the bolt - arrow - for catalytic converter exhaust bank 2.






Danger of causing damage to the coupling element.

• Do not bend the coupling element more than 10°.

• Do not stretch the coupling element.

• Do not damage the wire mesh on the coupling element.

- First, remove the "upper" catalytic converter for exhaust bank 2 in a downward direction. Then remove the catalytic converter for exhaust bank 1.

Installing

• Tightening specifications, refer to => [ Muffler Overview ] Muffler Overview and to => [ Exhaust Manifold Overview ] Exhaust Manifold Overview.

• Replace gaskets and self-locking nuts.

• During installation, all cable ties must be installed at the same location.

- First, place the "lower" catalytic converter of exhaust bank 1 in the installation position. Then install the catalytic converter for exhaust bank 2.

The rest of the installation is performed in reverse order of removal, noting the following:

- Install the driveshaft to the front final drive.

- Install the transfer case support.

- Install the oxygen sensors. Refer to => [ Oxygen Sensors ] Oxygen Sensors.

- Install the throttle valve control module.

- Install the exhaust system free of stress. Refer to => [ Exhaust System, Installing ] Exhaust System, Installing.

- On a vehicle with air suspension, deactivate vehicle lift mode.