Audi Workshop Service and Repair Manuals

Removing and installing intake manifold

Removing   Note All cable ties which are released or cut open when removing must be fitted in the same position when installing. –  Remove front left cover -arrows-. –  Note (if necessary obtain) code on vehicles with coded radio / radio and navigation system (RNS). –  Disconnect earth wire at battery with ignition switched off.

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

–  Unscrew bolt -arrow- and remove cover over coolant expansion tank.

–  Remove air pipe -arrows-.

–  Unplug electrical connector -arrow- at Hall sender -G40-.

–  Detach electrical connectors -1- at injectors and 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 release pressure by carefully loosening the connection. –  Disconnect fuel supply pipe -1- and fuel return pipe -2- by pressing release tabs.

–  Detach vacuum line -2- from intake manifold.   Note Disregard -item 1-.

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

Vehicles with exhaust temperature control: –  Unplug electrical connector -arrow- at exhaust gas temperature sender 1 -G235-.

All vehicles: –  Remove bolts -2- and -3- and detach retaining plate -4- from dipstick guide tube. –  Disengage coolant hose -1- from retaining plate. –  Move retaining plate to the side (hoses remain connected). Vehicles with exhaust gas temperature control: –  Unscrew exhaust gas temperature sender 1 -G235- from intake manifold. All vehicles: –  Detach crankcase breather hose from bottom of intake manifold and move hose clear. –  Unbolt support for intake manifold from intake manifold. –  Unbolt and remove intake manifold from cylinder head.   Note Block off intake ports in cylinder head with clean rags. 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. 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
Intake manifold support to intake manifold	20
Hose clips for air hoses	3.5