Audi A3 Workshop Service and Auto Repair Manuals

Removing and installing intake manifold Removing   Note t  The following description is for removal and installation on vehicles with secondary air system. Some operations may not be required for earlier vehicles. t  All cable ties which are released or cut open when removing must be fitted in the same position when installing. –  Note (if necessary obtain) code on vehicles with coded radio / radio and navigation system (RNS). –  Disconnect earth wire at battery with ignition switched off.

–  Take off engine cover panel -arrows-.

–  Remove cover in front of intake manifold -arrows-.

–  Detach pipe for secondary air system from brackets on engine -arrows-.

–  Remove bolts -2- and -3- and detach bracket for dipstick guide tube -4-. –  Unplug connectors -1- for turbocharger air recirculation valve -N249- and secondary air inlet valve -N112- on underside of retainer for electrical change-over valves. –  Detach vacuum hose going to electrical change-over valves from intake manifold.

–  Unbolt support -1- for intake manifold from intake manifold. –  Detach vacuum hose -2-.

Vehicles with hoses routed according to version 1: –  Detach vacuum line -arrow- going to brake servo at intake manifold.

Vehicles with hoses routed according to version 2: –  Detach vacuum line -arrow- going to brake servo.

All models: –  Unplug electrical connectors -1- at intake air temperature sender -G42- and -4- at throttle valve module -J338- (bottom). –  Detach vacuum line -3- leading to activated charcoal filter and air intake hose -2- from throttle valve module -J338-.

Vehicles with throttle cable: –  Disengage nipple -1- on end of throttle cable from cable cam. –  Pull grooved section of throttle cable sheath -4- out of rubber grommet -2- at support bracket -5-.   Note Retaining clip -3- remains connected.

All models: –  Unplug electrical connector -arrow- at Hall sender -G40-.

–  Unplug electrical connectors -1- on injectors. –  Unclip retaining strip from fuel rail -2-.

WARNING The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then dissipate pressure by carefully unfastening the connection. –  Disconnect fuel supply pipe -1- and fuel return pipe -2- by pressing release tabs. –  Move fuel supply pipe and fuel return pipe clear. –  Disconnect crankcase breather hose from T-piece. –  Pull out oil dipstick. –  Unbolt and remove intake manifold from cylinder head.   Note Block off intake ports in cylinder head with clean cloths. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew seals and gaskets. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. Vehicles with throttle cable: –  Adjust throttle cable. All models:   Note t  When the battery is reconnected, please ensure that the vehicle equipment (e.g. radio, radio/navigation system, clock, electric window lifters) is activated as described in the operating instructions. t  For further operations after reconnecting power supply, refer to → Rep. Gr.24. Tightening torques

Component		Nm
Intake manifold to cylinder head		10
Support for intake manifold to:	Intake manifold	20
	Bracket	45
Fuel rail to intake manifold		10
Hose clips for air hoses		3.5