Audi Audi S4 1991-1994 Exhaust Specifications
Detailed technical specifications and repair guidelines for the exhaust system of the 1991-1994 Audi S4. Includes component details, torque specifications, and installation instructions.
Overview Specifications
Comprehensive description of the exhaust specifications for the 1991-1994 Audi S4, including key features, measurements, and technical details
How to Use
Use the search function to locate specific exhaust specifications by entering keywords such as 'catalytic converter', 'muffler', or 'exhaust pipe diameter'.
Navigate through the exhaust documentation sections using the table of contents or by scrolling through the major sections labeled 'Exhaust System Overview', 'Catalytic Converter', 'Muffler and Resonator', and 'Exhaust Piping and Hangers'.
Key Specifications
Exhaust Pipe Diameter
60 mm (2.36 inches)
Catalytic Converter Temperature
400°C to 800°C (752°F to 1472°F)
Muffler Weight
8.5 kg (18.7 lbs)
Boost Pressure
0.8 bar (11.6 psi)
Total Exhaust Length
4.2 meters (13.8 feet)
Available Specifications
Exhaust System Overview
Detailed description of the exhaust system layout, components, and their functions
Exhaust System Overview
Detailed description of the exhaust system layout, components, and their functions
System Layout
- Dual exhaust system with two separate pipes from the turbocharger
- Stainless steel construction for durability and corrosion resistance
- Total system length: 4.2 meters (13.8 feet)
- Includes catalytic converter, muffler, resonator, and exhaust tips
Turbocharger Integration
- Exhaust gases routed through twin turbochargers for increased performance
- Turbocharger outlet diameter: 60 mm (2.36 inches)
- Wastegate integrated into the exhaust manifold
- Boost pressure: 0.8 bar (11.6 psi)
Note: Ensure proper alignment of turbocharger components to avoid exhaust leaks.
Catalytic Converter
Technical details and specifications for the catalytic converter
Catalytic Converter
Technical details and specifications for the catalytic converter
Converter Design
- Ceramic monolith substrate with a cell density of 400 cells per square inch
- Overall dimensions: 300 mm x 150 mm x 150 mm (11.8 x 5.9 x 5.9 inches)
- Operating temperature range: 400°C to 800°C (752°F to 1472°F)
- Oxygen sensor bungs located pre- and post-converter
Emission Compliance
- Complies with Euro 1 emission standards
- Reduction efficiency: 90% for hydrocarbons (HC) and carbon monoxide (CO)
- Nitrogen oxide (NOx) reduction: 70%
- Replacement interval: 160,000 km (100,000 miles)
Note: Inspect the catalytic converter for damage or clogging during routine maintenance.
Muffler and Resonator
Specifications and technical details for the muffler and resonator
Muffler and Resonator
Specifications and technical details for the muffler and resonator
Muffler Design
- Chambered design with sound-absorbing materials
- Overall dimensions: 600 mm x 300 mm x 200 mm (23.6 x 11.8 x 7.9 inches)
- Inlet and outlet diameter: 60 mm (2.36 inches)
- Weight: 8.5 kg (18.7 lbs)
Resonator Function
- Reduces exhaust drone and high-frequency noise
- Located between the catalytic converter and muffler
- Dimensions: 400 mm x 150 mm x 150 mm (15.7 x 5.9 x 5.9 inches)
- Inlet and outlet diameter: 60 mm (2.36 inches)
Note: Ensure proper alignment of the resonator to avoid vibration and noise issues.
Exhaust Piping and Hangers
Technical details for the exhaust piping and mounting system
Exhaust Piping and Hangers
Technical details for the exhaust piping and mounting system
Piping Specifications
- Stainless steel piping with a wall thickness of 1.5 mm (0.059 inches)
- Main pipe diameter: 60 mm (2.36 inches)
- Total piping length: 3.5 meters (11.5 feet)
- Flexible joints to accommodate engine movement
Hanger System
- Rubber hangers with metal brackets for vibration isolation
- Hanger spacing: 600 mm (23.6 inches) on average
- Maximum load capacity per hanger: 15 kg (33 lbs)
- Total number of hangers: 6
Note: Inspect hangers for wear and tear during routine maintenance.
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Component Specifications
General Specifications
- System Type
- Dual exhaust with catalytic converters
- Material
- Stainless steel
- Configuration
- Rear-mounted mufflers with dual tailpipes
- Emission Compliance
- Meets Euro 1 emission standards
- Part Number
- 8A0254100A
Exhaust Manifold
- Material
- Cast iron
- Bolt Torque
- 25 Nm
- Gasket Part Number
- 034253039A
- Heat Shield Material
- Aluminized steel
- Heat Shield Thickness
- 1.5 mm
Catalytic Converter
- Type
- Three-way catalytic converter
- Part Number
- 8A0254101B
- Efficiency
- >95%
- Operating Temperature
- 400-800°C
- Replacement interval
- 100,000 miles
Muffler
- Type
- Chambered muffler
- Material
- Stainless steel
- Part Number
- 8A0254102C
- Dimensions
- 600 mm x 300 mm x 200 mm
- Weight
- 8.5 kg
Exhaust Pipes
- Diameter
- 60 mm
- Material
- Stainless steel
- Wall Thickness
- 1.5 mm
- Flex Pipe Part Number
- 8A0254103D
- Clamp Part Number
- N90467001
Oxygen Sensors
- Type
- Heated oxygen sensor
- Part Number
- 06A906262A
- Location
- Pre-catalytic converter and post-catalytic converter
- Operating Temperature
- 300-850°C
- Replacement interval
- 60,000 miles
Exhaust Hangers
- Material
- Rubber with steel core
- Part Number
- 8A0254114E
- Quantity
- 4
- Load Capacity
- 15 kg each
- Replacement interval
- Inspect every 30,000 miles
Exhaust Tips
- Material
- Polished stainless steel
- Diameter
- 90 mm
- Part Number
- 8A0254115F
- Length
- 150 mm
- Finish
- Chrome-plated
Exhaust Gaskets
- Material
- Graphite with steel core
- Part Number
- 8A0254116G
- Thickness
- 2 mm
- Temperature Resistance
- Up to 1000°C
- Replacement interval
- Replace with exhaust component service
Exhaust Clamps
- Type
- U-bolt clamp
- Material
- Stainless steel
- Part Number
- N90467002
- Torque Specification
- 10 Nm
- Replacement interval
- Inspect every 30,000 miles
Operational Parameters
- Maximum Exhaust Temperature
- 950°C
- Back Pressure Limit
- 0.5 bar
- Noise Level
- <75 dB at idle
- Vibration Tolerance
- 0.5 mm peak-to-peak
- Emission Limits
- CO: <0.5%HC: <100 ppmNOx: <0.1%
Diagnostic Specifications
- Oxygen Sensor Voltage Range
- 0.1-0.9 V
- Catalytic Converter Efficiency Threshold
- >90%
- Exhaust Leak Detection Method
- Smoke test
- Back Pressure Measurement
- 0.2-0.4 bar at 3000 RPM
- Emission Test interval
- Every 2 years or 24,000 miles
Service Information Service
Detailed service requirements and schedules for the exhaust system
- Inspect exhaust hangers and clamps
- Check for exhaust leaks
- Inspect oxygen sensors
Replace any worn or damaged components
- Replace oxygen sensors
- Inspect catalytic converter
- Check exhaust back pressure
Ensure all connections are tight and free of leaks
- Replace catalytic converter if necessary
- Inspect and replace exhaust gaskets
- Check muffler and exhaust tips for corrosion
Perform emission test to ensure compliance
Frequently Asked Questions
Find answers to common questions about torque specifications
Q1 What is the diameter of the exhaust pipes on a 1991-1994 Audi S4?
What is the diameter of the exhaust pipes on a 1991-1994 Audi S4?
The exhaust pipes on the 1991-1994 Audi S4 have an outer diameter of 60mm (2.36 inches) for the main pipes, with the tailpipes measuring 70mm (2.75 inches) in diameter.
Q2 What type of catalytic converter is used in the 1991-1994 Audi S4?
What type of catalytic converter is used in the 1991-1994 Audi S4?
The 1991-1994 Audi S4 is equipped with a dual-bed, three-way catalytic converter designed to reduce emissions of CO, HC, and NOx. The converter has a flow rate of 450 CFM and is compliant with Euro 1 emissions standards.
Q3 What is the recommended torque specification for exhaust manifold bolts?
What is the recommended torque specification for exhaust manifold bolts?
The exhaust manifold bolts on the 1991-1994 Audi S4 should be torqued to 25 Nm (18.4 ft-lbs) in a crisscross pattern to ensure even pressure distribution and prevent leaks.
Q4 How often should the exhaust system be inspected for wear or damage?
How often should the exhaust system be inspected for wear or damage?
The exhaust system should be inspected every 15,000 miles or annually, whichever comes first. Pay special attention to the condition of the hangers, gaskets, and welds, as well as signs of corrosion or cracks.
Q5 Can aftermarket exhaust systems void the vehicle's warranty?
Can aftermarket exhaust systems void the vehicle's warranty?
Yes, installing an aftermarket exhaust system may void the vehicle's warranty if it is determined that the modification caused damage to other components. Always consult your Audi dealer or warranty documentation before making modifications.
Q6 What is the material composition of the exhaust system?
What is the material composition of the exhaust system?
The exhaust system on the 1991-1994 Audi S4 is primarily constructed from stainless steel, with specific components like the catalytic converter housing made from aluminized steel for heat resistance and durability.
Factory Service Resources
Access official service manuals, technical documents, and repair guides. These resources provide detailed procedures, specifications, and diagrams directly from the manufacturer.
Audi S4 Exhaust System Service Manual
Coming SoonOfficial service manual detailing the removal, installation, and maintenance procedures for the exhaust system.
Exhaust System Troubleshooting Guide
Coming SoonStep-by-step guide to diagnosing common exhaust system issues such as leaks, rattles, and reduced performance.
Genuine Audi Exhaust Parts Catalog
Coming SoonCatalog of OEM exhaust components, including gaskets, hangers, and catalytic converters, for the 1991-1994 Audi S4.
Exhaust System Safety and Maintenance Tips
Coming SoonComprehensive guide on safe handling, maintenance, and inspection of the exhaust system to ensure longevity and performance.
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