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.

• ‒ → Disconnect hose -1- going to upper coolant pipe.
• ‒ Unbolt coolant expansion tank -2- (-arrows-).
• ‒ Disconnect wire for coolant shortage indicator switch -F66 and move coolant expansion tank to one side.

Note:

Do not disconnect coolant hose -3-.

Vehicles with cruise control system

• ‒ Disengage actuatorrod at throttle valve control part.

• ‒ Pull vacuum hose offvacuum unit.

All models

• ‒ → Disconnect air intake hose at intake pipe connection and air mass meter -arrows-.

• ‒ → Remove cover over injectors -arrows on right-.

• ‒ → Detach throttle cable at the throttle valve control part and at support bracket (do not remove throttle cable retainer). Move throttle cable clear to the side.
• ‒ Disconnect vacuum hose -2- for ACF valve.
• ‒ Disconnect vacuum hose -1- for brake servo.

• ‒ → Unplug connector -1- at throttle valve control part -J338.
• ‒ Move wiring clear.

Vehiclesä 07.97:

• ‒ Unplug connector -2- at intake air temperature sender -G42.

Vehicles08.97 ä:

• ‒ → Disconnect wires/unplug connectors as follows:

•     1 -    intake air temperature sender -G42
•     2 -    Intake manifold change-over valve -N156

All models

• ‒ → Remove intake air pipe -arrows-.

Note:

Detach hoses under intake air pipe after removing pipe.

• ‒ → Fit hose clamps 3094 on coolant hoses going to throttle valve control part.
• ‒ Disconnect coolant hoses from throttle valve control part.

Note:

Throttle valve control part is shown in illustration with engine removed.

• ‒ → Pull connector off Hall sender -G40 -arrow-.

• ‒ → Unscrew retaining bolts for fuel distributor railand disconnect vacuum line from fuel pressure regulator -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.

• ‒ → Unbolt intake manifold from the two bottom supports -arrows-.

• ‒ → Unbolt intake manifold from cylinder head -arrows- and remove.

Note:

Plug intake ports on cylinder head with clean cloths.

Installing

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

Note:

Replace gaskets and seals.

• ‒ Adjust throttle cable
• ‒ Fill cooling system => Page 19-7
• ‒ After connecting battery, enter anti-theft code for radio

=> Radio operating instructions

• ‒ 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

=> Motronic injection and ignition system (4-cylinder)07.96 ä; Repair group 24; Testing throttle valve control part; Performing adaptation of throttle valve control part

Tightening torques