5KCSTQ: Front exhaust pipe R&R help!

[Beatty, Robert]

Randy,

I did the exact same repair last summer.  The motor mount had failed
cracking my downpipe and breaking a few exhaust studs.  I pulled the head,
pipe and turbo.  Other than all the fuel lines and the airbox being in the
way, its not too hard to get that downpipe off.  Just reaching all the
various bolts are a major pain in the a$$.  Have a good selection of wrenchs
cause you will prolly need 2 different ones to get some of them.  The
downpipe bolts into the back of the turbo and is secured with 4 bolts, the
wastegate has 3 bolts and the cat connection has 4 bolts. 

Incidently, the replacement pipe I had was also cracked, so I took it to a
welding shop and had them weld it.  He "double" welded it for me and I put
it in the car.  No problems yet.

While you are there, make sure none of your exhaust studs are broken.  They
CAN be changed in the car but its a ROYAL pita.  Certain dealers even made
up a jig to allow drilling out of the studs while still in the car.  I can't
envision doing this without a 90deg drill and ALOT of patience.

If you do end up pulling the head to do studs, change your head gasket,
seals, timing belt, and water pump.  Your already there so might as well do
it.  My 1st time doing this took me most of the 4th of July weekend, but I
struggled through it and actually enjoyed it.  BTW, don't forget to ensure
the coolant line on the back of the head is connected correctly or it will
leak coolant all over the place, its really hard to see if its on right
thats why I mention it.

Any other questions, feel free to ask.

Rob 
87 5ktq

-----Original Message-----
From: randy paquette [mailto:iqtpilot at hotmail.com]
Sent: Monday, April 09, 2001 10:57 AM
To: quattro at audifans.com
Subject: 5KCSTQ: Front exhaust pipe R&R help!


Firstly, thanks to all that commented regarding radiator sources.  Upon 
further examination of my car I have found that my front exhaust pipe has a 
large crack.  This is the pipe that goes from the Turbo to the wastegate and

on to the front of the CAT.
My concern is R&R of this - our own Chris Semple can get me one but I was 
hoping for some feedback regarding disconnection from the wastgate and 
turbo.  Am I going to ruin anything (i.e. breaking bolts) trying to get this

out?  Unhooking from the cat will be no problem.
I plan to replace the hot side motor mount, O2 sensor and tie rod on that 
side when I do this.  Anything else that should be considered?

Thanks again!!!!
Randy...
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