Audi Workshop Service and Repair Manuals

Removing and installing intake manifold (top section)

Removing   Note All cable ties which are released or cut open when removing must be refitted in the same position when installing. –  Pull off engine cover (rear) -arrows-.

–  Pull off engine cover (front) -arrows-.

–  Pull non-return valve -1- off connection at air intake hose. –  Remove air intake hose. To do so, release hose clip -2- and clamps -arrows-.

–  Unplug electrical connectors. 1 -  Variable intake manifold flap change-over valve -N239- 2 -  Variable intake manifold position sender -G513- –  Pull off the vacuum hoses -arrow A- and -arrow B-. USA models: –  Disconnect vacuum hose -arrow C- leading to leak diagnostic pump.

All models: –  Unplug electrical connectors. 1 -  Inlet camshaft control valve 1 -N205- 2 -  Throttle valve module -J338- 3 -  Activated charcoal filter solenoid valve 1 -N80- 4 -  Intake air temperature sender -G42- / intake manifold pressure sender -G71- 5 -  Intake manifold flap valve -N316- –  Move electrical wiring harness clear.

–  Detach vacuum hoses -arrows-. –  Detach active charcoal filter system solenoid valve 1 -N80--item 1- from throttle valve module -J338-.

–  Pull crankcase breather hose off pressure control valve -arrow-.   Note Shown from rear with engine removed for illustration purposes.

–  Unscrew bolts -arrows- and detach intake manifold (top section).   Note Seal intake ports on cylinder heads with clean cloths. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets, seals and O-rings. t  Fit all cable ties in the original positions when installing. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. Tightening torque

Component	Nm
Intake manifold (top section) to intake manifold (bottom section)	6 1)
Hose clips (9 mm wide)	3
l  1) Tighten in stages and in diagonal sequence