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 fitted in the same position when installing. –  Drain off coolant from engine → Chapter.

–  Remove engine cover panel -arrows-.

–  Remove caps (left and right) -arrows-.

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

–  Disconnect all six spark plug connectors -arrows-.

–  Unscrew ignition coils -arrows- and remove with ignition cables. –  Remove crankcase breather hose from cylinder head cover (right-side).

Vehicles without secondary air system: –  Carefully detach vacuum pipes -arrows-. –  Unplug electrical connectors at variable intake manifold change-over valve -N156--item 3- and intake air temperature sender -G42--item 4-. –  Unscrew bolts -2- of retaining plate for variable intake manifold change-over valve. –  Detach retaining plate and disconnect hose from intake connecting pipe. –  Unscrew bolt of air intake connection -1- and detach intake connecting pipe. –  Unscrew nuts -5- and move vacuum unit downwards.

Vehicles with secondary air system: –  Unplug electrical connectors -2- and -4-. –  Carefully disconnect vacuum hoses -1-, -3-, -5-, -6- and -7-. –  Unbolt the retaining plate for solenoid valves -arrows-.

Vehicles with throttle cable and cruise control system: –  Detach vacuum hose -2- at vacuum unit for cruise control. –  Unscrew bolts -1- and move vacuum unit downwards.

All models: –  Unplug electrical connectors -1- and -2-. –  Disconnect hose connection -3- leading to brake servo. –  Detach vacuum hose -4- at solenoid valve 1 for activated charcoal filter system -N80-.

–  Detach hose -2-. –  Unscrew bolt -4- and detach air duct -1- with seal from throttle valve module. –  Detach hose -3- and take out air duct. Vehicles with throttle cable: –  Disengage cruise control operating rod at throttle valve module. –  Disengage throttle cable at throttle valve housing and support bracket (do not remove retainer). Move throttle cable clear to the side.

All models: –  Unscrew earth wire -2- at rear of cylinder head (right-side). –  Disconnect coolant hoses -1- and -3- from throttle valve module and from coolant pipe (rear). –  Unplug electrical connectors at all injectors. –  Move wiring harness and crankcase breather pipe clear of intake manifold. Vehicles with secondary air system: –  Disconnect vacuum hose at secondary air combination valve.

All models: –  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  Renew self-locking nuts, gaskets and seals. 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. –  Fill cooling system → Anchor. Vehicles with throttle cable: –  Check adjustment of throttle cable → Rep. Gr.20. Tightening torques

Component			Nm
Intake manifold to cylinder head			10
Fuel pipes to fuel rail/fuel pressure regulator			23
Air duct to intake manifold			10