Audi Workshop Service and Repair Manuals

Removing and installing intake manifold (bottom section) with fuel rail Special tools and workshop equipment required

t  Assembly tool -T10118-

t  Holder for 5/16 inch bits -V.A.G 1766/2- from TORX bit set -V.A.G 1766-

t  Bit -3320/2- (tool -3320- is not required) Removing   WARNING The fuel system is pressurised. The fuel pressure in the high-pressure part of the injection system must be reduced to a residual pressure prior to opening; for procedure see → Chapter. –  Remove regulating flap control unit -J808- → Chapter „Removing and installing regulating flap control unit -J808-“. –  Remove intake manifold → Chapter „Removing and installing intake manifold“.

–  Remove union nuts -arrows- and bolt -1- and detach high-pressure pipe.

–  Unplug electrical connector -2- at fuel pressure sender -G247--1-.

–  Pull wiring duct for injectors out of both clips -1-. –  Unscrew securing bolts -arrows- from intake manifold (bottom section).   Note

t  Use holder for 5/16 inch bits -V.A.G 1766/2- and bit -3320/2- to unscrew securing bolt -arrow-. t  If you only want to remove the the bottom section of the intake manifold, make sure the injectors remain in the cylinder head. If necessary, have a second mechanic hold the injectors in position. t  Reason: If the injectors are removed, the combustion chamber ring seals and the support ring must be renewed. –  Carefully detach intake manifold (bottom section) from injectors. Installing –  The remaining installation steps are carried out in the reverse sequence. l  Tightening torque → Chapter „Intake manifold (bottom section), fuel rail, injector - exploded view“ –  Install intake manifold (top section) → Chapter „Removing and installing intake manifold“.