Audi Workshop Service and Repair Manuals > A4 Cabriolet Mk2 > Power unit | 4-cylinder TDI injection and glow plug system (1.9 ltr.; 2.0 ltr. unit injector, 2 valve) | Fuel preparation system Diesel injection | Servicing diesel direct injection system | Removing and installing intake manifold with exhaust gas recirculation cooler (engine codes BKE, BPW, BRB, BRC)

Removing and installing intake manifold with exhaust gas recirculation cooler (engine codes BKE, BPW, BRB, BRC)

Removing

–	Drain off coolant → Rep. gr.19.

–	Unclip cover caps.

–	Unscrew nuts -arrows- and detach engine cover panel.

–	Remove insulation beneath cover.

–	Re-insert dipstick in guide tube.

–	Unplug electrical connector -1-.

–	Remove bolt -2-.

–	Remove air pipe -arrows-.

–	Remove bolts -arrows-.

–	Remove air ducts -1- and -2-.

–	Unplug electrical connector -1- at air mass meter -G70-.

–	Loosen hose clip -2- to remove air intake hose.

–	Move clear wiring harness at air cleaner housing and remove air cleaner housing -arrow-.

–	Unplug electrical connectors:

1 -	On exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer -G212-

2 -	On intake manifold flap motor -V157-

–	Disconnect air intake hoses -1- and -2-.

–	Remove nuts -3-.

–	Remove bolts -arrows-.

–	Take off intake manifold together with exhaust gas recirculation cooler.

Installing

Installation is carried out in the reverse order; note the following:

Note

t	Renew gaskets and self-locking nuts.

t	Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue.

–	When installing air intake hoses with plug-in connectors, ensure that the securing clip -arrow- engages audibly on the retaining lug -A-.

–	Fill cooling system → Rep. gr.19.

Tightening torques

Component

Intake manifold to cylinder head

EGR connecting pipe to:

Exhaust gas recirculation cooler

Exhaust manifold

25 ¹⁾

l	¹⁾ Renew self-locking nuts.

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