Under no circumstances should the exhaust system fall during installation, otherwise the ceramic body in the catalytic converter may be damaged and the converter will become unusable.
Vehicles with all-wheel drive have two mufflers. To replace one muffler, cut the connecting pipe. The place of separation is shown in the figure. Dimension a is 244 mm
Be sure to purchase self-locking nuts when purchasing spare parts. The seals and used circlips should also be replaced. Vehicles with all-wheel drive and vehicles with six-cylinder engines have two mufflers.
The nut on the spacer between the exhaust pipes in a vehicle with a six-cylinder engine is tightened to a torque of 23 Nm
1. Place the vehicle on jack stands so that it is resistant to vibrations.
2. If necessary, remove the lower engine cover. Spray all bolted connections of the exhaust system with a rust remover, wait a while until the rust dissolves.
3. Support the exhaust system or hang it with a wire from the underbody of the vehicle so that it does not fall and damage the catalytic converter. Disconnect the oxygen sensor connectors.
4. The front and additional muffler are fitted as one piece as standard. If only the muffler needs to be replaced, cut the connecting pipe at a right angle in the place indicated by the recess (using a special saw VAG 1523). Front silencer and additional muffler in case of repair are supplied separately as spare parts, together with a repair double clamp (adapter sleeve).
Location of the exhaust pipe. The exhaust pipe in a car with a four-cylinder engine must be cut at a right angle in the marked place (arrow)
5. The sleeve should be placed so that the cut is in the middle of the sleeve. According to Audi regulations, the bolt heads must point downwards.
Repair double clamp (adapter sleeve) 1 is placed so that the cut is in the middle
6. When installing all parts of the exhaust system, first mount freely, tighten the bolted connections on the flanges and clamps by hand.
7. The exhaust system aligns when cold and stress-free. On vehicles with adapter sleeves between the front silencer and the secondary silencer, the front silencer must also be aligned.
8. To do this, move the exhaust system forward (arrow) so that at the front right near the front silencer, the pretension at the locking loop is a=7...9 mm. Then tighten the bolt connections of the front adapter sleeve evenly to a torque of 40 Nm (position 22 in the figure, which shows the exhaust system for a four-cylinder engine).
Installing the front muffler
9. Slide the back of the system forward in this way (arrow), to pretension the locking loop (or locking loops in the case of a 3.0 l engine) at the rear of the additional muffler was a = 7... 11 mm.
Installing an additional silencer
10. Tighten bolts evenly.
11. To make the bolted joints loosen more easily later, lubricate them with high temperature paste.
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