Audi Workshop Service and Repair Manuals

Removing

Note:

All cable ties which are released or cut open when removing must be fitted in the same position when installing.

• ‒ Obtain radio code on vehicles with coded radio.
• ‒ With ignition switched off disconnect battery earth strap.
• ‒ Remove engine cover.
• ‒ Draining cooling system

• ‒ → Detach coolant hoses -1- and -3-.
• ‒ Unbolt coolant expansion tank -2- arrows.
• ‒ Disconnect wire for coolant shortage switch -F66 and move expansion tank clear to the side.

• ‒ → Detach throttle cable at throttle valve control part and at support bracket -arrows- (do not remove securing clip).
• ‒ Pull off vacuum hose -1- for ACF valve.
• ‒ Pull off vacuum hose -2- for brake servo

• ‒ → Pull off air intake hose and crankcase breather hose -arrows-.

• ‒ → Unplug connector -1- at throttle valve control part -J338.
• ‒ Move wiring clear.
• ‒ Pull off vacuum hose -2- for fuel pressure regulator.
• ‒ Unscrew retaining bolts for fuel distributor rail -arrows-.
• ‒ Pull fuel distributor rail together with injectors off intake manifold and place it on a clean cloth at the back of the engine compartment.
• ‒ Pull off hose going to bottom coolant pipe at throttle valve control part.

• ‒ → Pull off coolant hoses -1 ... 3-.
• ‒ Unbolt upper coolant pipe -arrows-.

• ‒ → Loosen bottom mountings -3-, -4- and -5- on front and rear brackets for intake manifold.
• ‒ Unscrew and remove top bolts -1- and -2- on brackets for intake manifold.
• ‒ Pull out oil dipstick.
• ‒ Unscrew nuts and bolts securing intake manifold to cylinder head.
• ‒ Take off intake manifold.

Note:

Plug intake ports on cylinder head with clean cloths.

Installing

Note:

Replace gaskets and seals.

Installation is carried out in the reverse order, when doing this note the following:

• ‒ Adjust throttle cable => Page 20-42
• ‒ Fill cooling system => Page 19-6
• ‒ After connecting battery terminals, enter anti-theft code for radio

=> Radio Instruction Manual

• ‒ Close windows fully using electric window switches.
• ‒ Then operate all electric window switches again for at least one second in the "close" direction to activate the automatic one-touch function.
• ‒ Set clock to correct time.
• ‒ Perform adaption of throttle valve control part:

=> Motronic injection and ignition system (4-cylinder); Repair Group 24; Checking throttle valve control part -J338; Performing basic setting of throttle valve control part -J338

Tightening torques