Audi Workshop Service and Repair Manuals

Removing and installing intake manifold

Removing –  Unclip air intake hose from air duct -arrows-.

–  Unplug electrical connector -2- at intake air temperature sender 2 -G299-. –  Detach vacuum hose -1- from actuator for intake air preheater.

–  Pull dipstick -1- out of guide tube. –  Remove the engine cover together with air cleaner housing -arrows-. –  Re-insert dipstick in guide tube.

–  Unplug electrical connector at solenoid valve 1 for activated charcoal filter system -N80-.

–  Unplug electrical connector -1- at throttle valve module -J338-. –  Unscrew bolts -arrows- and remove throttle valve module -J338-.

–  Remove bolts -arrows- for connecting pipe for exhaust gas recirculation at exhaust gas recirculation valve -N18- and remove gasket.

–  Detach vacuum hose -1- leading to solenoid valve 1 for activated charcoal filter system -N80- at intake manifold. –  Detach solenoid valve 1 for activated charcoal filter system -N80- from its retainers and move to side with vacuum hoses attached. –  Detach vacuum line -2- leading to brake servo at intake manifold. –  Unclip upper coolant pipe at intake manifold -arrows- and move forward.

–  Disconnect hose -2- for crankcase breather system at intake manifold by pressing release tabs. –  Unplug electrical connectors at intake manifold pressure sender -G71--item 1- and intake manifold flap air flow control valve -N316--item 3-.

–  Disconnect vacuum hose -arrow- at actuator for intake manifold change-over. –  Unscrew securing bolts -1- and -2- for intake manifold and lay intake manifold to rear.

–  Unplug electrical connector -arrow- at bolt. –  Unscrew fuel pressure sender -G247-. –  Lift intake manifold up and towards left. Installing   Note t  Make sure that no dirt etc. gets into the opened intake manifold. t  Renew gaskets and seals. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. –  Place intake manifold rearwards in engine compartment for the meantime. –  Screw in fuel pressure sender -G247-. –  Secure intake manifold to cylinder head. Remaining installation steps are carried out in reverse sequence; note the following: Tightening torques

Component	Nm
Intake manifold to fuel rail (bottom section of intake manifold)	20
Throttle valve connection to intake manifold	7
EGR connecting pipe to exhaust gas recirculation valve -N18-	8