Exhaust system, installing free of tension

2004 Audi A8SECTION Exhaust system, installing free of tension
  • Align exhaust system when cold.
  • Loosen threaded connections on all double clamps of exhaust system.
Fig 1: Pressing Rear Muffler Toward Front
GW00017420Courtesy of VOLKSWAGEN UNITED STATES, INC.
  • Press rear muffler toward front - arrow  - until following pre-loads on retaining loops are achieved:
  • Front retaining loop: - - = 11 mm.
  • Rear retaining loop: - - = 14 mm.
  • Align rear muffler horizontally.
  • Position double clamps centered to section points.
Fig 2: Adjusting Front Double Clamps So Bolt Ends Do Not Project Over Lower Edges Of Double Clamps
GW00018049Courtesy of VOLKSWAGEN UNITED STATES, INC.
  • Adjust front double clamps so that bolt ends do not project over lower edges of double clamps.
Fig 3: Adjusting Rear Double Clamps So That Bolt Ends Do Not Project Over Lower Edges Of Double Clamps
GW00028913Courtesy of VOLKSWAGEN UNITED STATES, INC.
  • Adjust rear double clamps so that bolt ends do not project over lower edges of double clamps.
  • Tighten threaded connections of double clamps evenly.

Tail pipes, aligning 

Fig 4: Checking Distance Of End Pipes At Left/Right To Bumper Cover
GW00017568Courtesy of VOLKSWAGEN UNITED STATES, INC.
  • Check distance of end pipes at left and right to bumper cover:
  • Dimension - - left = dimension - - right.

If necessary, correct dimension "x" as follows:

Fig 5: Locating Threaded Connections Of Brace Between Exhaust Pipes
GW00017569Courtesy of VOLKSWAGEN UNITED STATES, INC.
  • Loosen threaded connections - arrow  - of brace between exhaust pipes.
  • Adjust distance between rear mufflers.
  • Tighten bolts.
Fig 6: Checking Distances Of End Pipes To Bumper
GW00017570Courtesy of VOLKSWAGEN UNITED STATES, INC.
  • Check distances - - and - - of end pipes to bumper:
  • Dimension - - = 18 to 22 mm.
  • Dimension - - = 8 to 12 mm.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • You smell fuel, burning insulation, or see smoke.
  • Brakes feel soft, pull hard to one side, or make grinding noises.
  • The engine overheats, stalls repeatedly, or misfires under load.
  • You are missing required tools, torque specs, or safe lifting equipment.
  • You are not confident in the next step or safety outcome.