Audi Workshop Service and Repair Manuals

Removing and installing bottom section of intake manifold (right-side) Removing   WARNING t  Always read rules for cleanliness and instructions for working on fuel system → Chapter. t  Follow these instructions and rules for cleanliness before starting work and while working on the fuel system. –  Remove engine cover panel → Chapter. Vehicles with engine codes CAMA, CAMB, CCWA, CCWB, CGKA, CGKB, CCLA:

–  Unscrew bolts -arrows- and remove protective plate for high-pressure pipe. –  Remove union nuts -1- and -4- and detach high-pressure pipe.   Note Disregard -items 2 and 3-. Vehicles with engine code CAPA:

–  Unscrew union nuts -1 ... 4- and detach high-pressure pipes.

–  Take electrical connector -arrow- for exhaust gas temperature sender 2 -G448- out of bracket and unplug. All vehicles (continued): –  Remove top section of intake manifold → Chapter.

–  Unplug electrical connector -1- from air mass meter -G70-. –  Unscrew bolt -3- and move clear exhaust gas pressure sensor 1 -G450--item 4- at air pipe. –  Move clear electrical connector -2- for exhaust gas temperature sender 3 for cylinder bank 1 -G496- at air pipe. –  Remove air hose and air mass meter -G70-. To do so, release hose clip -5- and clamps -arrows-.

–  Unscrew bolts -left arrows-, detach air hose -right arrow- and remove air intake connection with air hose.

–  Remove air duct -arrow-.

–  Unplug electrical connector -2-. –  Remove bolts -1-.

–  Pull electrical connectors -1 and 2- out of bracket.   Note Connector -2- is not fitted in this location on vehicles with engine code CAPA. –  Unplug electrical connector -3- at intake manifold flap motor -V157-.

–  Carefully press connecting rod -1- off intake manifold flap motor -V157- (observe note).   Note t  Proceed carefully when pressing connecting rod off ball stud (risk of breaking). t  Bolt -2- is not fitted. –  Remove bolts -4-. –  Unplug electrical connectors at glow plugs for cylinders 1, 2 and 3. –  Move wiring harness clear to the side.

–  Remove bolts -arrows-. –  Press coolant pipe to one side and take out bottom section of intake manifold (right-side).   Note t  Disregard -item 1-. t  Block off intake ports in cylinder head with a clean rag. Installing l  Tightening torques: refer to intake manifold - exploded view → Chapter Installation is carried out in the reverse order; note the following:   Note Renew seals and/or gaskets. –  Install top section of intake manifold → Chapter. –  Install high-pressure pipes → Chapter. –  Check fuel system for leaks → Chapter.