1996 AUDI A4 catalytic converter

26-2


Mufflers with mountings, removing and
installing

1 -
40 Nm
2 -
From catalytic converter
3 -
Flat-head bolt
4 -
Double clamp
5 -
25 Nm
6 -
Mounting
With retaining ring
7 -
Front muffler
8 -
Double clamp (for repairs)
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26-5

Catalytic converter, removing and
installing


Removing

- Remove bolts -arrows- and take off engine cover panels -A ... C-.

- Remove air distributor component -arrows-.
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26-6

Right-hand catalytic converter:

Left-hand catalytic converter: - Disconnect connector -1- for oxygen sensor at bulkhead.

- Disconnect connector -2- for oxygen sensor at bulkhead.
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26-9


- Remove transmission support -arrows-.
- Loosen exhaust system clamp and push clamp towards muffler.

Note:
Avoid excessive bending of the flexible pipe connection (de-coupling
element) on the front exhaust pipe. The angle between the catalytic
converter and the front exhaust pipe must not exceed 10 , otherwise the
flexible connection will be damaged. - Loosen hose clamp -1- on turbocharger heat shield.
- Unbolt exhaust pipe -2- from turbocharger.
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26-11

Exhaust system, aligning free of stress

Align the exhaust system as follows to avoid
stresses in the system and prevent the
transmission of noise into the body:

Notes:

Before assembling the exhaust system, the
front exhaust pipes and the catalytic converters
must be aligned accurately and secured.
Loosen all bolted connections on the exhaust
system (except exhaust manifold and flange
mountings, catalytic converter/intermediate
pipe).
The exhaust system must be aligned when it is
cold.
Keep to the sequence described below.
The dimensions in the illustrations are
approximate.
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26-12

Vehicles without clamp between center and
rear muffler

- Loosen screws of front clamp between catalytic
converter and center muffler.

- Push exhaust system far enough forward (arrow) so that pre-tension at
retaining loop at rear right of rear muffler is -a- = 9 ... 11 mm.
- Tighten screws of front clamp between catalytic converter and main
muffler evenly to 40 Nm, installation position Page 26
-15
.
- Tailpipes, aligning

Dimension -b- between bumper cutout and lower edge of tailpipes must
also equal specification. - Align tailpipes so that distance -a- (left side) is equal to distance -a-
(right side).

Dimension b = 97 ... 103 mm
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26-13

Vehicles with clamp between front muffler
and rear muffler

Note:
It is only necessary to additionally align the front
muffler on vehicles with clamp fitted between
front muffler and rear muffler.

- Loosen bolted connections on front clamps
between catalytic converters and front muffler.

- Push exhaust system towards front of vehicle -arrow- so that rear left
mounting on front muffler is pre-loaded by a = 7 - 9 mm.
- Tighten bolts on front clamps between catalytic converters and front
muffler evenly to 40 Nm; installation position Page 26
-15
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26-16

Exhaust system, checking for leaks


- Start engine and run at idling speed.

- Plug tailpipe (e. g. with rag or stopper) and leave
plugged until check is complete.

- Listen for noise at connection points (cylinder
head/manifold, manifold/turbocharger,
turbocharger/catalytic converter, etc.) to locate
leaks.

- Correct any leaks that are found.
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pair&id=AUDI.B5.GE05.26.1