Attention. The rear and middle mufflers of the exhaust system are welded together, however, each of them can be replaced separately.
Position the vehicle above a pit or on a lift.
Remove the lower mudguard of the engine compartment.
V6 diesel vehicles
Remove the upper engine cover to gain access to the exhaust pipe-to-turbocharger connection flange.
Unscrew the bolts and remove the turbocharger heat shield (see fig. 4D.9).
Lubricate the nuts and bolts of the exhaust system components with a rust destroying agent and wait a while until the rust is completely destroyed.
Vehicles with petrol engines, except for 125hp engines.
Disconnect the lambda sensor electrical connector located on the bulkhead of the engine compartment. On vehicles with six-cylinder engines, there are 2 lambda sensors.
Unscrew the exhaust pipe from the exhaust manifold and from the bottom of the turbocharger.
Secure the exhaust system to the body with a soft wire to prevent the exhaust system from falling. Dropping the exhaust system can damage the catalytic converter.
Vehicles with 1.8-I petrol engine
Unscrew the exhaust pipe from the transmission bracket.
While supporting the exhaust system, release it from the suspension cushions and remove it from under the vehicle.
Installation
To facilitate the subsequent unscrewing of the nuts and bolts securing the system, lubricate them with Liqui Moly LM-508-ASC high-temperature paste.
Before re-assembling the elements of the exhaust system, clean their joint with sandpaper from the remnants of sealant and rust.
Attention. Always replace gaskets and self-locking nuts.
Vehicles with 1.8-I petrol engine
Screw the exhaust pipe to the transmission bracket.
Connect the exhaust pipe to the middle muffler with a double clamp, positioning it in such a way that the lower edge of the clamp mounting bolt is at the level of the extinguisher pipe (see fig. 4D.11). The bolts should be located on the left side of the pipe. Do not fully tighten the bolts at this stage.
Connect the middle and rear mufflers with a double clamp and align them with respect to each other.
Install the exhaust system components into the rubber suspension pads, but do not tighten the bolts at this stage.
Screw the front exhaust pipe to the exhaust manifold and the bottom of the turbocharger, while checking the correct installation of the gasket
Align the elements of the exhaust system and check that the system is installed freely, without tension and that the gap from the body elements must be at least 25 mm.
Vehicles with 125 hp engine
Prestress by moving the middle muffler forward 7-9mm (see fig. 4D.12) and secure it in this position. This is necessary so that during thermal expansion as a result of heating, the exhaust system is installed in the correct position.
Move the rear muffler forward a distance of 12-14 mm (see fig. 4D.13) and secure it in this position.
Check and, if necessary, adjust the distance between the rear of the exhaust pipe and the bumper, which must be at least 40 mm (see fig. 4D.14).
Finally tighten all bolts and nuts of fastening of elements of system of release of the fulfilled gases.
Tightening torques
- Exhaust manifold to cylinder head - 25 Nm.
- Double clamps - 40 Nm.
Six-cylinder engine
- Receiving exhaust pipe to the exhaust manifold - 25 Nm.
- Other flange connections - 30 Nm.
- Lambda sensor to catalytic converter - 50 Nm.
Engine 1.8-I
- Receiving exhaust pipe to gearbox bracket - 25 Nm.
Install the lower engine compartment mudguard.
Vehicles with petrol engines, except for 125hp engines.
Screw in the lambda sensor and connect its electrical connector.
V6 diesel vehicles
Install and bolt the turbocharger heat shield. Install and secure the engine cover.
Pic. 4D.3. Exhaust system for front-wheel drive vehicles AUDI A6 with a 1.8-I gasoline engine
1 - nut, 25 Nm,
2 - exhaust manifold (AJP engine),
3 - lambda sensor, 50 Nm,
4 - gasket,
5 - intake exhaust pipe,
6 - nut, 30 Nm,
7 - nut, 25 Nm,
8 - catalyst,
9 - suspension cushion,
10 - suspension bracket,
11 - bolt, 25 Nm,
12 - additional muffler,
13 - distance (a = 7-9 mm) pre-tensioning the cold exhaust system,
The arrow indicates the direction of movement,
14 - junction of the exhaust pipe,
15 - central muffler,
16 - double clamp, 40 Nm,
17 - junction of the exhaust pipe,
18 - middle muffler,
19- suspension,
20 - intake exhaust pipe,
21 - catalyst,
22 - puck.
Pic. 4D.4. Exhaust system for front-wheel drive vehicles AUDI A6 with a 1.9-I-TDI 110 hp diesel engine. and all-wheel drive vehicles
1 - additional muffler,
2 - middle muffler,
When replacing a muffler, cutting must be done at a distance of 140-150 mm in front of the central muffler.
3 - suspension cushion,
4 - bolt, 25 Nm,
5 - suspension cushion,
6 - double clamp, 40 Nm,
7 - intermediate pipe,
8 - nut, 25 Nm,
9 - turbocharger,
10 - gasket,
11 - catalytic converter,
12 - bolt, 25 Nm,
13 - gasket,
14 - nut, 25 Nm
Pic. 4D.5. Exhaust system for front-wheel drive vehicles AUDI A6 with a V6 diesel engine
1 - catalytic converter,
2 - double clamp,
3 - nut, 40 Nm,
4 - suspension cushion,
5 - suspension cushion,
6 - nut, 25 Nm,
7 - rear muffler,
8 - double clamp,
9 - nut, 40 Nm,
10 - muffler,
11 - suspension,
12 - bolt, 25 Nm,
13 - bolt, 25 Nm,
14 - suspension pad,
15 - bolt, 25 Nm,
16 - gasket,
When installing, a new gasket must be used.
17 - turbocharger,
18 - nut, 25 Nm.
Pic. 4D.6. Exhaust manifolds and exhaust pipes on AUDI A6 vehicles with a V6 petrol engine
1 - bushing,
2 - bolt,
3 - washer,
4 - bracket,
5 - bushing,
6 - rubber bushing,
7 - nut, 25 Nm,
8 - spring,
9 - bolt, 25 Nm,
10 - to the middle mufflers,
11 - left exhaust pipe with catalytic converter,
12 - lambda sensor No. 2, 50 Nm,
13 - 4-pin black electrical connector,
14 - nut, 25 Nm,
15 - cap, 10 Nm,
16 - branch pipe,
17 - upper heat shield,
18 - lower heat shield,
19 - left exhaust manifold,
20 - gasket,
When installing, a new gasket must be used.
21 - right exhaust manifold,
22 - oxygen sensor No. 1, 50 Nm,
23 - right exhaust pipe with catalytic converter.
Pic. 4D.7. Central and rear muffler on AUDI A6 front wheel drive vehicles with V6 petrol engine
1 - nut, 40 Nm,
2 - from the catalytic converter,
3 - bolt,
4 - double clamp,
5 - bolt, 25 Nm,
6 - suspension cushion,
7 - middle muffler,
8 - suspension bracket,
9 - suspension cushion,
10 - rear muffler,
11 - double clamp,
13 - silencer.
Note. The rear muffler on 4WD vehicles is similar to the muffler shown in fig. 4D.8.
Pic. 4D.8. System of release of the fulfilled gases on all-wheel drive cars AUDI A6
1 - nut, 25 Nm,
2 - suspension cushion,
3 - nut, 40 Nm,
4 - bolt,
5 - double clamp, 40 Nm,
6 - place for cutting the pipe,
7 - rear right muffler,
8 - suspension cushions,
9 - suspension brackets,
10 - rear left muffler,
11 - connecting pipe,
12 - gasket,
13 - catalytic converter,
14 - turbocharger,
15 - double clamp, 40 Nm,
16 - middle muffler.
Pic. 4D.10. Exhaust pipe support bracket parts
1 - buffer,
2 - bushing,
3 - washer,
4 - right pad,
5 - washer,
6 - bolt,
7 - bushing,
8 - left overlay,
9 - spring,
10 - bolt,
11 - self-locking nut, 25 Nm.
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