Audi Cars 1999-05

Exhaust Manifold

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Removal & Installation



1.8L Engine
  1. Remove the turbocharger.
  2.  
  3. Seal any openings in the turbo with clean shop rags to prevent debris from entering.
  4.  
  5. Remove the exhaust manifold mounting nuts, and then remove the manifold.
  6.  
  7. Seal openings in the cylinder head and exhaust pipe with clean shop rags to prevent debris from entering.
  8.  

To install:

  1. Remove the shop rags from the cylinder head, install the exhaust manifold and tighten the mounting nuts to 18 ft. lbs. (25 Nm).
  2.  
  3. Remove the shop rags from the turbo and exhaust pipe, and then install the turbo.
  4.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Cylinder head cover
     
    Intake manifold cover
     
    Turbocharger to charcoal filter hose
     
    Upper air pipe and heat shield
     
    Turbocharger
     
    Exhaust manifold nuts
     
    Exhaust manifold
     

  4.  
  5. Clean the gasket mounting surfaces.
  6.  

To install:

  1. Install or connect the following:

    Exhaust manifold using a new gasket. Torque the nuts to 18 ft. lbs. (25 Nm).
     
    Turbocharger. Torque the bolts for 2001-03 to 22 ft. lbs. (30 Nm) and for 2004 to 25 ft. lbs. (35 Nm)
     
    Upper air pipe and heat shield. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Turbocharger to charcoal filter hose
     
    Intake manifold cover
     
    Cylinder head cover
     

  2.  

2.7L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove engine
  4.  
  5. Remove turbocharger
  6.  
  7. Remove exhaust manifold
  8.  

To install:

  1. Install exhaust manifold and tighten to 18 ft. lbs. (25 Nm)
  2.  

2.8L Engine
Left Manifold
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove or disconnect the following:

    Heated Oxygen (O 2 S) sensor
     
    Exhaust system from the manifold
     
    Coolant tube from the cylinder head
     
    Heat shield
     
    Exhaust Gas Recirculation (EGR) tube from the rear of the manifold
     
    Exhaust manifold nuts
     
    Exhaust manifold
     

  8.  
  9. Clean all gasket mating surfaces.
  10.  

To install:

  1. Install or connect the following:

    Manifold using a new gasket. Torque the nuts to 18 ft. lbs. (24 Nm)
     
    Exhaust system to the manifold using a new gasket
     
    HO 2 S sensor
     
    EGR tube to the rear of the manifold
     
    Heat shield
     
    Coolant tube to the cylinder head
     
    Negative battery cable
     

  2.  
  3. Fill the engine with coolant.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

Right Manifold
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Heated Oxygen (HO 2 S) sensor
     
    Exhaust system from the manifold
     
    Heat shield
     
    Manifold nuts
     
    Exhaust manifold
     

  4.  
  5. Clean all gasket mating surfaces.
  6.  

To install:

  1. Install or connect the following:

    Exhaust manifold using a new gasket. Torque the nuts to 18 ft. lbs. (24 Nm)
     
    Heat shield
     
    Exhaust system to the manifold using a new gasket
     
    HO 2 S sensor
     
    Negative battery cable
     

  2.  
  3. Start the vehicle, check for leaks and repair if necessary.
  4.  

2.8L V6 Engine

Right Exhaust Manifold Removal

  1. To remove the right side exhaust manifold:
  2.  
    1. Disconnect the negative battery cable.
    2.  
    3. Detach and remove the heated Oxygen (O 2 S) sensor.
    4.  
    5. Unbolt the exhaust system from the manifold.
    6.  
    7. Remove the heat shield.
    8.  
    9. Remove the manifold nuts, then the manifold.
    10.  
    11. Clean all gasket mating surfaces.
    12.  


To install:

  1. Install the manifold using a new gasket, and tighten the mounting nuts to 18 ft. lbs. (24 Nm).
  2.  
  3. Install the heat shield.
  4.  
  5. Connect the exhaust system to the manifold using a new gasket.
  6.  
  7. Install, then attach the heated O 2 S sensor.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Enter the radio security code.
  12.  
  13. Start the vehicle and check for leaks.
  14.  

Left Exhaust Manifold Removal

  1. To remove the left side exhaust manifold:
  2.  
    1. Disconnect the negative battery cable.
    2.  
    3. Drain the engine coolant into a sealable container.
    4.  
    5. Detach and remove the Oxygen (O 2 S) sensor.
    6.  
    7. Unbolt the exhaust system from the manifold.
    8.  
    9. Unbolt, and if necessary, remove the coolant tube from the cylinder head.
    10.  
    11. Remove the heat shield.
    12.  
    13. Disconnect the Exhaust Gas Recirculation (EGR) tube from the rear of the manifold.
    14.  
    15. Remove the manifold nuts, then the manifold.
    16.  
    17. Clean all gasket mating surfaces.
    18.  


To install:

  1. Install the manifold using a new gasket, and tighten the mounting nuts to 18 ft. lbs. (24 Nm).
  2.  
  3. Connect the exhaust system to the manifold using a new gasket.
  4.  
  5. Install, then attach the heated O 2 S sensor.
  6.  
  7. Connect the EGR tube to the rear of the manifold.
  8.  
  9. Install the heat shield.
  10.  
  11. Attach the coolant tube to the cylinder head.
  12.  
  13. Fill the engine with coolant.
  14.  
  15. Connect the negative battery cable.
  16.  



Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold mounting and related components-2.8L 5V V6 engine

3.0L Engine
Left Manifold
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Covers, components and electrical connections for access
     
    Exhaust system from the manifold
     
    Heat shield
     
    Manifold nuts
     
    Exhaust manifold
     

  4.  
  5. Clean all gasket mating surfaces.
  6.  

To install:

  1. Install or connect the following:

    Exhaust manifold using a new gasket. Torque the nuts to 18 ft. lbs. (25 Nm)
     
    Heat shield. Torque M6 bolts to 84 inch lbs. (10 Nm) and M8 bolts to 18 ft. lbs. (25 Nm)
     
    Exhaust system to the manifold using a new gasket
     
    Covers, components and electrical connections
     
    Negative battery cable
     

  2.  
  3. Start the vehicle, check for leaks and repair if necessary.
  4.  

Right Manifold
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable.
     
    Covers, components and electrical connections for access (mark connections for reinstallation)
     
    Right front exhaust pipe with catalytic converter
     
    Secondary air injection valve bolts (resonator remains installed)
     
    Dipstick guide tube
     
    Heat shield bracket
     
    Heat shield
     
    Exhaust manifold nuts
     
    Exhaust manifold
     

  4.  
  5. Clean all gasket mating surfaces.
  6.  

To install:

  1. Install or connect the following:

    Manifold using a new gasket. Torque the nuts to 18 ft. lbs. (25 Nm)
     
    Heat shield and bracket. Torque M6 bolts to 84 inch lbs. (10 Nm) and M8 bolts to 18 ft. lbs. (25 Nm)
     
    Dipstick guide tube
     
    Secondary air injection line bolts
     
    Covers, components and electrical connections
     
    Negative battery cable
     

  2.  
  3. Fill the engine with coolant.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

3.2L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold
     
    Heat shield
     
    Remove 7 nuts and washers on both exhaust manifolds
     
    Pull exhaust manifolds towards the rear and remove
     

  4.  

To install:

  1. Installation is the reverse of the removal procedure, using the following torque values:

    Exhaust manifold to cylinder head 17 ft. lbs (23 Nm)
     
    Exhaust pipe to manifold 29 ft. lbs (40 NM)
     

  2.  

Both Manifolds

NOTE
This procedure requires engine removal. See ENGINE ASSEMBLY section.

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Dipstick tube (LH manifold only)
     
    Exhaust system from the manifold
     
    Heat shield
     
    Manifold nuts
     
    Exhaust manifold
     

  4.  
  5. Clean all gasket mating surfaces.
  6.  

To install:

  1. Install or connect the following:

    Exhaust manifold using a new gasket. Torque the nuts to 18 ft. lbs. (25 Nm)
     
    Heat shield
     
    Exhaust system to the manifold using a new gasket
     
    Dipstick tube
     
    Negative battery cable
     

  2.  
  3. Reinstall engine assembly.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

 
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