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  1. #1
    Senior Member Three Rings tamaneri's Avatar
    Join Date
    Apr 02 2007
    AZ Member #
    16915
    Location
    New Jersey (Northern)

    swapping the downpipe

    Hey guys,

    I have my car jacked up. I am trying to replace the down pipe. My current down pipe is raped.

    Anyway. I was wondering how you would get access to the bolts that connect the test pipe to the down pipe. One of them is semi easy to access, the other 2 look rather difficult to access due to a heat shield that protects the cv boot from the hot downpipe/test pipe.


    What tool would you normally use and how would you go about doing it? thanks guys.
    Taylor A. Maneri

    2003 A4 1.8TQ B6 Black/Black
    Unitronic Stage 2 | TT 386cc injectors | RAI test pipe | Magnaflow 16601 | Milltek downpipe | Forge 007 DV | rs4 rear sway | vent pod boost gauge | JHM short throw | 034 engine mounts | ARP snub | ECS RA4 stage 1 clutch/flywheel | Bilstein / H&R
    tamaneri (AIM)

  2. #2
    Veteran Member Four Rings old guy's Avatar
    Join Date
    Dec 28 2006
    AZ Member #
    14483
    My Garage
    '13 A5, '24 Tiguan SEL R-Line
    Location
    Western Maryland

    There are DIY's here for both down pipe and test pipe replacement. The DIY's are for a B5 but the B6 is essentially the same. It may help a little to have the visuals: Clicky click
    '03 A4 5-MT Motoza tuned Frankenturbo F21L With full supporting mods. Sold (and missed dearly).
    '13 A5 6-MT Needs more Fun Stuff: Neuspeed PM / 3.0 TDI Intercooler / H&R OE Sport Springs / Bilstein B8 Shocks / TyrolSport Brake Stiffeners / ECS Short Shifter / S5 Side Skirts / RS Grille

  3. #3
    Senior Member Three Rings tamaneri's Avatar
    Join Date
    Apr 02 2007
    AZ Member #
    16915
    Location
    New Jersey (Northern)

    Thanks for the DIY. It helps a little bit. I am stuck trying to get the top bolt off where the test pipe connects to the down pipe. I got the other 2 (3 total connect it together).

    There just doesn't seem to be a good angle to knock that bolt loose!
    Taylor A. Maneri

    2003 A4 1.8TQ B6 Black/Black
    Unitronic Stage 2 | TT 386cc injectors | RAI test pipe | Magnaflow 16601 | Milltek downpipe | Forge 007 DV | rs4 rear sway | vent pod boost gauge | JHM short throw | 034 engine mounts | ARP snub | ECS RA4 stage 1 clutch/flywheel | Bilstein / H&R
    tamaneri (AIM)

  4. #4
    Active Member One Ring sherwin@034's Avatar
    Join Date
    Apr 08 2010
    AZ Member #
    57376
    My Garage
    Late 2001 vw passat
    Location
    Bay Area, California

    Have you tried Disconnecting the cat from the turbo and loosening up the clamp connecting the "midpipe" from the rest of the downpipe? By doing that you can slide the whole assembly towards you giving you a little more room to play with.

  5. #5
    Established Member Two Rings
    Join Date
    Sep 08 2010
    AZ Member #
    63823
    Location
    Asheville, NC

    i stripped 3 or 3 bolts to my cat when installing my test pipe and ended up having to cut the downpipe in half and re welding it after. save alot of time. BUT dont strip them is what im saying. the downpipe and cat/testpipe wont come out together.

  6. #6
    Senior Member Three Rings tamaneri's Avatar
    Join Date
    Apr 02 2007
    AZ Member #
    16915
    Location
    New Jersey (Northern)

    still working on this.. LOL.

    i have 2 bolts reconnected on the new downpipe where it connects to the test pipe. working on the other one.....
    Taylor A. Maneri

    2003 A4 1.8TQ B6 Black/Black
    Unitronic Stage 2 | TT 386cc injectors | RAI test pipe | Magnaflow 16601 | Milltek downpipe | Forge 007 DV | rs4 rear sway | vent pod boost gauge | JHM short throw | 034 engine mounts | ARP snub | ECS RA4 stage 1 clutch/flywheel | Bilstein / H&R
    tamaneri (AIM)

  7. #7
    Senior Member Three Rings tamaneri's Avatar
    Join Date
    Apr 02 2007
    AZ Member #
    16915
    Location
    New Jersey (Northern)

    Hey guys. I have everything back on. However, there seems to be a small leak where the downpipe connects to the rest of the exhaust system.

    I was unable to use the stock clamp (i guess the milltek downpipe is slightly longer than the stock one). If I used it, the rest of the exhaust wouldn't line up properly and I couldn't bolt it back in place.

    I have the midpipe connecting directly to the downpipe. However, The clamp won't get tight enough, hence the leak. I bought a universal pipe clamp from Pep Boys, it said was 2.5", but I tighten it all of the way and it's still loose as a goose.

    What the heck else can I use/do?
    Taylor A. Maneri

    2003 A4 1.8TQ B6 Black/Black
    Unitronic Stage 2 | TT 386cc injectors | RAI test pipe | Magnaflow 16601 | Milltek downpipe | Forge 007 DV | rs4 rear sway | vent pod boost gauge | JHM short throw | 034 engine mounts | ARP snub | ECS RA4 stage 1 clutch/flywheel | Bilstein / H&R
    tamaneri (AIM)

  8. #8
    Veteran Member Four Rings EBG 18T's Avatar
    Join Date
    Mar 27 2005
    AZ Member #
    5877
    Location
    The Cold North

    Quote Originally Posted by tamaneri View Post
    What the heck else can I use/do?
    My solution was:

    2001 A4 1.8TQM (in pieces..)
    2020 Chevy AEV ZR2

  9. #9
    Active Member One Ring sherwin@034's Avatar
    Join Date
    Apr 08 2010
    AZ Member #
    57376
    My Garage
    Late 2001 vw passat
    Location
    Bay Area, California

    2.25" clamp should do the trick

  10. #10
    Veteran Member Four Rings PRY4SNO's Avatar
    Join Date
    Jun 28 2007
    AZ Member #
    19133
    My Garage
    1990 Coupe quattro with all the parts
    Location
    Edmonton, AB

    To access the downpipe at the test pipe I found removing the heatshield to be easiest.

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