mike01s4's Step by Step Audi S4 Downpipes Removal Instructions:
by Mike Shimon (VAST Performance)
One of the best tips...cover all the little places in
the engine where parts could fall into...also...ESPECIALLY the bellhousing
behind the motor..it's got big holes in there..so cover them up with duct
tape or something.
Tools:
(note: not every tool listed will necessarily be required)
3/8" drive ratchet, short handle
3/8" drive ratchet, 6" handle, tilt head
1/2" drive ratchet
1/4" universal swivel joint
3/8" universal swivel joint
1/2" universal swivel joint
5mm allen wrench
6mm allen wrench
5mm socketed allen
6mm socketed allen
1/2" drive O2 sensor socket (deep 22mm with a slotted side)
1.5' to 2' of 1/2" drive extension for the 02 sensorsocket
3/8" drive extensions (6",3")
1/4" drive extension (6")
17mm short handle, 12-point box wrench
17mm universal joint socket
22mm box wrench
10mm box wrench
7 - 13mm sockets, 1/4" drive
Phillips screwdrivers
Flat head screwdrivers
Steps:
disconnect battery ground
remove all engine covers
remove air box inlet tubing
remove air box
remove flex tubing to y-pipe
remove y-pipe
put coolant reservoir tank out of the way (disconnect lower sensor)
remove outlet hoses from y-pipe
remove the turbo inlet pipes, and be careful when removing the wiring harness retainer clips
plug all intake holes with some rags
on the intermediate firewall behind each cylinder bank, remove the wiring harnesses, brackets and open connections
jack front end of vehicle at least a foot into the air
use good jackstands and place them so they do not get in the way of the dp removal,
i.e...the rear circular aluminum mounts (be careful not to crush them)
also jack up the rear and place on jackstands
remove the allen head bolts for the dp heat shields
make sure the 1st O2 sensors are disconnected, then remove
remove the passenger side exhaust gas temperature sensor (17mm), be sure not to ruin the
head
remove any 17mm dp flange nuts that you can from up top
remove the shields above each inner cv joint on the driveshafts -remove any leftover 17mm dp flange nuts
remove the 2nd O2 sensors
completely remove the dp pipe support brackets where each dp starts to bend
disconnect rearward exhaust parts, do not leave the exhaust sleeve clamps attached to the dp's
remove the heatshield clamps
remove the heatshields and try to get the dp's out without the flange scraping everything
this is the best part:
INSTALL IS REVERSE OF REMOVAL :p...SUUUUUUUUURE
for the 2nd O2 sensors, you have two options:
1. you can splice in about 8" of new wire, then heat shrink it all up to extend them
2. you can cut all the wore harness clips above the drivetrain, and pull the sensors towards the rear while maintaining the sheath over the wires.
(on my car, I did #1 because I had the equipment to do it, and I didn't want to remove the
stock placement)...i've also done # 2 before, but it's a bit of a pain removing one of
the nylon ties...you need a long screwdriver in there and just need to twist it so it breaks
be sure to put some anti-seize on the 02 sensor threads and dp flange studs
if you really want to be perfect...replace the 8 17mm nylon lock dp flange nuts and the dp flange gaskets
get everything loosely fitted, and the heatshields located properly, but not screwed in or
tightened down whatsoever...then start tightening the flange nuts
04/22/02
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