AUDI A4 1995 B5 / 1.G AWM Engine Exhaust System Components Owner's Manual

26-21

Exhaust manifold, removing and
installing


Removing

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

- Remove engine cover panel -arrows-.

- Remove air filter cover -arrow-.
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26-22


- Remove bolts -arrows-.
- Remove air duct -1- and -2-.

- Disconnect wiring connectors as follows:
1 - on ACF valve (in addition, remove ACF valve from air filter housing)
2 - on mass air flow sensor
3 - on Wastegate Bypass Regulator valve -N75-
- Remove hose connections, move wiring aside and remove air filter
housing -arrows-.
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26-23


- Remove sound insulation -arrows-.

- Loosen bolts -1- and -2- by several turns.
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26-24


- Remove front hose from line of crankcase vent -2-.
- Disconnect front hose from line -1- of secondary air inlet.
- Remove heat shield -3-.

- Remove bolts -1- and -2- of oil feed line.
- Remove bolts -3- for exhaust turbocharger.
- Remove seal between exhaust turbocharger and exhaust manifold.
- Plug opening in suction duct of turbocharger with a clean cloth.
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26-25


Installing
Installation is carried out in the reverse order of removal; note the
following:
Note:
Always replace seals, gaskets and self-locking nuts. - Remove all nuts -arrows- on exhaust manifold.
- Remove washers and exhaust manifold.
- Adhere to the following sequence:

Exhaust manifold to cylinder head
Exhaust turbocharger on exhaust manifold
Turbocharger bracket to cylinder block
Turbocharger bracket to turbocharger
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26-26

Tightening torques

Component
Nm
Exhaust manifold to cylinder head 30
Turbocharger to exhaust manifold
35
1)
2)
Turbocharger bracket to cylinder block
25
Turbocharger bracket to turbocharger
30
Oil feed line to cylinder head 23
Line of crankcase vent to cylinder
head
10
Hose clamps for air duct hoses
3.5

1) Replace bolts
2) Coat thread and head attachment area with
high temperature lubricant "G 052 112 A3"
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26-27

Catalytic converter, removing and
installing


Removing

- Remove heat shield -arrows- above right-hand drive shaft.
- Loosen bolted connection front exhaust pipe/catalytic converter
accessible from below.

Note:
The flexible connection in the front exhaust pipe must not be deflected
more than 10 to avoid damage. - Remove bolt for transmission bracket to exhaust system -arrow-.
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26-28


Note:
Coolant hoses -1- and -3- do not have to be disconnected. - Unbolt coolant expansion tank -2-, -arrows-.
- Disconnect wire to Engine Coolant level (ECL) Warning switch -F66-
and move coolant expansion tank to one side.

- Disconnect wiring connector for oxygen sensors and move wiring
aside.
1 - (brown) to oxygen sensor downstream of catalytic converter -G130-
2 - (black) to oxygen sensor upstream of catalytic converter -G39-
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26-29


- Remove air filter cover -arrow-.

- Remove bolts -arrows-.
- Remove air duct -1- and -2-.
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26-30


- Disconnect wiring connectors as follows:
1 - on ACF valve (in addition, remove ACF valve from air filter housing)
2 - on mass air flow sensor
3 - on Wastegate Bypass Regulator valve -N75-
- Disconnect hose connections, move wiring aside and remove air filter
housing -arrows-.
- Loosen bolted connection of front exhaust pipe/catalytic converter
accessible from above.

- Undo bolts -arrows- of exhaust turbocharger/catalytic converter.
- Remove catalytic converter upward.
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