Audi Workshop Service and Repair Manuals

Removing and installing intake manifold

Removing –  Release quick-release fasteners and remove engine cover panel -arrows-. –  Drain coolant → Chapter.

–  Detach coolant hoses -1 and 3-. –  Unbolt coolant expansion tank -2--arrows-. –  Detach electrical wiring at coolant shortage indicator switch -F66- on coolant expansion tank (bottom).

–  Detach vacuum hoses -1 ... 3-. –  Unplug electrical connectors: 4 -  On intake air temperature sender -G42- 5 -  On throttle valve module -J338- –  Disconnect air hose -6- from throttle valve module.

–  Unbolt retaining plate for solenoid valves -arrows- located below intake manifold.   Note The electrical connectors -1 and 2- and vacuum hoses remain attached.

–  Unplug electrical connector -arrow- at Hall sender -G40-.

–  Remove bolts for fuel rail and disconnect vacuum line from fuel pressure regulator -arrows-. –  Pull fuel rail together with injectors off intake manifold and set it aside on a clean cloth in rear of engine compartment.   Note Make sure the removed injectors do not become soiled.

–  Detach coolant hoses from top coolant pipe. –  Move electrical wiring on top coolant pipe clear. –  Unbolt top coolant pipe from intake manifold and from coolant flange on rear of cylinder head -arrows-.

–  Remove support for intake manifold -arrows-. –  Detach hose -1- leading to solenoid valve 1 for activated charcoal filter -N80- from intake manifold. –  Pull out oil dipstick. –  Remove bracket for dipstick guide tube. –  Unbolt intake manifold from cylinder head and remove.   Note Block off intake ports in cylinder head with clean rags. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets and O-rings. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. –  Observe notes on procedure for connecting the battery → Rep. Gr.27. –  Fill up with coolant → Anchor. Tightening torques

Component		Nm
Intake manifold to cylinder head		10
Support for intake manifold to:	Bracket for ancillaries	20
	Intake manifold	20
Coolant pipe (top) to:	Intake manifold	10
	Coolant flange	10
Fuel rail to intake manifold		10
Hose clips for coolant hoses		2
Hose clips for air hoses		3.5