AUDI A4 1996 B5 / 1.G AWM Engine Exhaust System Components Owner's Guide

26-31

Installing
Installation is carried out in the reverse order of
removal; note the following:

Note:
Always replace seals, gaskets and self-locking
nuts.

- Grease threads of oxygen sensors with high
temperature lubricant G 052 112 A3. Apply
lubricant only to threads of sensors; the lubricant
must not get into the slots on the sensor body.

- Align exhaust system stress-free Page 26
-34

or Page 26
-37
.

Tightening torques

Components
Nm
Oxygen sensor to catalytic converter 55
Catalytic converter to exhaust turbocharger 30
Front exhaust pipe to catalytic converter 25
Front exhaust pipe to mountings on
transmission 25
Heat shield to transmission 23
Hose clamps for air duct hoses
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3.5
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26-32

Front exhaust pipe, removing and
installing


Removing

- Loosen bolted connection of front exhaust
pipe/catalytic converter accessible from above.

- Remove heat shield -arrows- above right-hand drive shaft.
- Remove crosspiece for underfloor.

- Unbolt transmission bracket for exhaust system -arrow-.
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26-33

Note:
The flexible connection in the front exhaust pipe
must not be deflected more than 10 or it may
be damaged.

Installing
Installation is carried out in the reverse order of removal; note the
following:
Note:
Always replace seals, gaskets and self-locking nuts.
Tightening torques - Separate exhaust system at clamp -arrows-.
- Loosen bolted connection of front exhaust pipe/catalytic converter
accessible from below.
- Remove front exhaust pipe.
- Align exhaust system stress-free Page 26
-34
or Page 26
-37
.
Components
Nm
Front exhaust pipe to catalytic converter 25
Crosspiece for underbody to body 20
Heat shield to transmission 23
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26-34

Stress-free alignment of the exhaust
system - Vehicles with front wheel drive


Vehicles without clamp between center
muffler and rear muffler

The exhaust system must be aligned when
cold.

- Loosen bolted connections on front clamp -Item
16 -, Page 26
-5 .

Aligning tailpipes - Push exhaust system toward front of vehicle -arrow- so that rear
mounting of rear muffler is pre-loaded by amount -a- = 9 to 11 mm.
- Tighten bolted connections on clamp evenly to 40 Nm.

Align tailpipes so that the distance -a- is the same on both sides.
At the same time, distance -b- must be obtained between the bumper cut-
out and the tailpipe:

Dimension b = min. 24 mm
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26-35

Vehicles with clamp between center muffler
and rear muffler

The exhaust system must be aligned when
cold.

Note:
It is only necessary to additionally align the
center muffler on vehicles with a clamp installed
between the center and rear mufflers.

- Loosen bolted connections on front -Item 16 -,
Page 26
-5 and rear clamps -Item 21 -, Page
26
-6 .

- Push front section of exhaust system toward front of vehicle -arrow-
until preloading at right-hand mounting of center muffler is -a- = 7 to 9
mm.
- Tighten bolts on front clamp -Item 16 -, Page 26
-5 evenly to 40 Nm.
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26-36


Aligning tailpipes - Push rear part of exhaust system towardsfront of vehicle -arrow- so
that rear mounting on rear muffler is preloaded by -a- = 9 to 11 mm.
- Tighten bolts on rear clamp -Item 21 -, Page 26
-6 evenly to 40 Nm.

Align tailpipes so that distance -a- is the same on both sides.
At the same time, distance -b- must be obtained between the bumper cut-
out and the tailpipe:

Dimension b = min. 24 mm
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26-37

Stress-free alignment of exhaust system
- Vehicles with all-wheel drive


Vehicles without clamp between centre
silencer and rear silencer
The exhaust system must be aligned when
cold.

- Loosen bolted connections on clamp -Item 15 -,
Page 26
-12


Aligning tailpipes - Push rear silencer towards front of vehicle -arrow- so that rear right
mounting on rear silencer is preloaded by a = 9...11 mm.
- Tighten bolted connections on clamp evenly to 40 Nm.

- Align tailpipes so that distance -a- is the same on both sides.
- At the same time, distance -b- must be obtained between bumper cut-
out and tailpipe:

Dimension b = min. 24 mm
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26-38

Vehicles with clamp between centre silencer
and rear silencer
The exhaust system must be aligned when
cold.

Note:
It is only necessary to additionally align the
centre silencer on vehicles with clamp fitted
between centre silencer and rear silencer.

- Slacken bolted connections on clamp -Item 15 -,
Page 26
-12
and -Item 22 -, Page 26
-14
.

- Push exhaust system towards front of vehicle -arrow- so that rear right
mounting on centre silencer is preloaded by a = 7...9 mm.
- Tighten bolts on front clamp -Item 15 -, Page 26
-12
evenly to 40
Nm.
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26-39


Aligning tailpipes - Push rear silencer towards front of vehicle -arrow- so that rear right
retainer on rear silencer is preloaded by a = 9...11 mm.
- Tighten bolts on rear clamp -Item 22 -, Page 26
-14
evenly to 40 Nm.

- Align tailpipes so that distance -a- is the same on both sides.
- At the same time, distance -b- must be obtained between bumper cut-
out and tailpipe:

Dimension b = min. 24 mm
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