AUDI A6 1996 C5 / 2.G AEB ATW Engines Exhaust System Components Owner's Manual

26-16

All-wheel-drive vehicles

- Using VAG1523 saw, cut exhaust pipe at separating point (arrow) at
right angle.
- When installing, center double clamp over separating point.

Double clamp installation position: level with bolts in clamp -1- pointing
toward left-rear wheel
- Install double clamp so that bolts don't project over lower edge of
double clamp Page 26
-13
, Fig. 3
.
- Align exhaust system free of stress Page 26
-24
.
- Tighten double clamp bolts evenly to 40 Nm (30 ft lb).
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26-17

Exhaust manifold, removing and
installing


Removing

Note:

Replace gaskets and self-locking nuts.
Flexpipe in front exhaust pipe must not be bent
more than 10 , otherwise it may be damaged.

- Remove air guide duct between cowl and air
cleaner housing.

- Remove air cleaner housing cover.

- Remove the following lines/harness connectors:
1 - At wastegate bypass regulator valve -N75-
2 - At Evaporative Emissions (EVAP) purge regulator valve -N80-
3 - At power output stage -N122-
4 - At Mass Air Flow (MAF) sensor -G70-
- Pull off hose connections and remove air cleaner housing (arrows).
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26-18


- Remove noise insulation panel (arrows).

- Unthread bolts -1- and -2- several turns.
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26-19

- Remove engine covers.

- Unbolt crankcase ventilation hose -1- at cylinder head cover and heat
shield.
- Unbolt both oil supply line bolts -2-.
- Remove heat shield -3-.
- Remove bolts -4-.
- Remove seal between turbocharger and exhaust manifold.
- Seal opening in turbocharger using clean cloth.

- Remove all nuts (arrows) from exhaust manifold.
- Remove washers and exhaust manifold.
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26-20

Installing
Installation is the reverse of removal, noting the
following:

- Install in sequential order as follows:


Exhaust manifold to cylinder head

Turbocharger to exhaust manifold

Turbocharger bracket to cylinder block

Tightening torques

Component
Tightening
torques
Turbocharger bracket to
turbocharger (bolt and washer
assembly M8) 40 Nm (30 ft
lb)
Turbocharger bracket to cylinder
block 45 Nm (33 ft
lb)
Turbocharger to exhaust
manifold 35 Nm (26 ft
lb)
Exhaust manifold to cylinder
head 25 Nm (18 ft
lb)
Oil supply line to cylinder head 20 Nm (15 ft
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lb)
Crankcase ventilation line to
cylinder head 10 Nm (7 ft
lb)
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26-21

Three Way Catalytic Converter (TWC),
removing and installing


Removing

Note:

Replace gaskets and self-locking nuts.
Flexpipe in front exhaust pipe must not be bent
more than 10 , otherwise it may be damaged.

- Disconnect harness connector for heated oxygen sensor (arrow) and
set aside.

Note: - Remove coolant expansion tank -2- (arrows)
- Remove wiring from Engine Coolant Level (ECL) warning switch -F66-
and lay coolant expansion tank to side.
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Coolant hoses -1- and -3- remain connected.
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26-22

- Remove air guide duct between cowl and air
cleaner housing.

- Remove air cleaner housing cover.

- Remove the following lines/harness connectors:
1 - At wastegate bypass regulator valve -N75-
2 - At Evaporative Emissions (EVAP) purge regulator valve -N80-
3 - At power output stage -N122-
4 - At Mass Air Flow (MAF) sensor -G70-
- Pull off hose connections and remove air cleaner housing (arrows).
- Remove Heated Oxygen Sensor (HO2S) from Three Way Catalytic
Converter (TWC).
- Remove bolts between front exhaust pipe and Three Way Catalytic
Converter (TWC).
- Unbolt transmission mount for exhaust system at exhaust system.
- Remove bolts between three Three Way Catalytic Converter (TWC)
and turbocharger.
- Remove Three Way Catalytic Converter (TWC) toward top.
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26-23

Installing
Installation is the reverse of removal, noting the
following:


Only grease threads of oxygen sensor with
"G 052 112 A3." Do NOT allow grease to get
into slots on sensor body.

Align exhaust system free of stress Page 26
-24
.

Tightening torques

Components
Tightening
torques
Front exhaust pipe to three way
catalytic converter 25 Nm (18 ft
lb)
Front exhaust pipe to
transmission mount 25 Nm (18 ft
lb)
Three way catalytic converter to
turbocharger 30 Nm (22 ft
lb)
Heated oxygen sensor to three
way catalytic converter 50 Nm (37 ft
lb)
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