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 refitted in the same position when installing. –  Drain off coolant → Chapter.

–  Remove engine cover panel -arrows-.

–  Remove cover -1- on left side of engine compartment.

–  Remove cover -1- at right of engine compartment.

–  Remove bolts -arrows-. –  Disengage activated charcoal filter solenoid valve 1 -N80--item 1- at air duct. –  Remove air duct -2-.

–  Remove air intake hose between air mass meter -G70- and air duct at intake manifold -arrows-.   WARNING The fuel system is pressurised. Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection. –  Disconnect fuel supply pipe -2- and fuel return pipe -1-.

–  Remove cover panel for cylinder head cover (left and right) -arrows-.

–  Pull off all six spark plug connectors -arrows-.

–  Unplug electrical connector -1-. –  Unscrew ignition coils -arrows- and remove with ignition cables. –  Remove crankcase breather pipe from cylinder head cover (right-side). –  Move the crankcase breather pipe clear.

–  Unplug electrical connectors -2- and -4-. –  Carefully disconnect vacuum hoses -1-, -3-, -5-, -6- and -7-. –  Unbolt the retaining plate for solenoid valves -arrows-. –  Detach vacuum hose leading to combination valves for secondary air system.

–  Unplug electrical connectors -1- and -2-. –  Disconnect hose connection -3- leading to brake servo. –  Disconnect hose -4- for crankcase breather system at pressure control valve. –  Detach vacuum hose -5- leading to activated charcoal solenoid valve 1 -N80- at throttle valve module -J338-.

–  Unscrew bolt -arrow- and pull air duct -2- off throttle valve module -J338-. –  If fitted, pull hose -1- off at air duct.   Note Illustration shows air duct from rear with engine removed.

–  If fitted, unscrew earth wire -2- from rear of cylinder head (right-side). –  Disconnect coolant hoses -1- and -3- from throttle valve module -J338- and from coolant pipe (rear). –  Unplug electrical connectors at all injectors. –  Move wiring harness at intake manifold clear.

–  Unscrew and remove intake manifold -arrows-.   Note Seal intake ports on cylinder heads with clean cloths. Installing Installation is carried out in the reverse order; note the following:   Note t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. t  All cable ties which are released or cut open when removing must be refitted in the same position when installing. t  Renew gaskets and seals.

–  Tighten bolts on intake manifold in stages and in diagonal sequence -arrows-. –  Connect vacuum hoses → Chapter. –  Fill cooling system → Anchor. Tightening torques

Component	Nm
Intake manifold to cylinder head	10
Air duct to intake manifold	10
Retaining plate for solenoid valves to intake manifold / air duct	10
Ignition coils to power steering pump	10
Fuel supply line to fuel rail	25