Audi Workshop Service and Repair Manuals

Removing and installing intake manifold - vehicles with engine code letters AMF, BHC Special tools and workshop equipment required

t  Hose clip pliers -VAS 6340-

Removing –  Remove bonnet → Rep. Gr.10. –  If fitted, unclip bracket -1-. –  Take off engine cover panel -arrows-. –  Remove noise insulation beneath cover.

–  Lever off caps -3- and -4- on two-piece windscreen wiper arm with a screwdriver. –  Slacken nuts on two-piece windscreen wiper arm a few turns. –  Release arms -1- and -2- one by one by tilting them slightly on the wiper shafts. –  Remove nuts completely and take off two-piece windscreen wiper arm.

–  Disconnect washer fluid hose -3-. –  If fitted, unplug electrical connectors -4- and -5- for heated washer jets. –  Open hose clip -6- using hose clip pliers -V.A.G 1921- and detach water drain hose from cowl panel grille. –  Pull off rubber seal -1- on cowl panel grille. –  Disconnect cowl panel grille -2-.

–  Unscrew nuts and bolts -arrows-. –  Pull fresh air duct forwards and remove by turning it to right side of vehicle.

–  Detach air hose -2- at mechanical exhaust gas recirculation valve and move clear to one side. –  Disconnect vacuum hose -3- at mechanical exhaust gas recirculation valve. –  Disconnect vacuum hose -4- from vacuum unit for intake manifold flap. –  Detach crankcase breather hose -1- and move clear to one side.

–  Remove noise insulation -arrows-.

–  Remove heat shield for exhaust manifold -arrows-.

–  Remove connecting pipe for exhaust gas recirculation -arrows-.

–  Unscrew bolts -arrows- and remove intake manifold. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets, seals and self-locking nuts. t  Charge air system must be free of leaks. 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. –  Install windscreen wiper arm → Rep. Gr.92. Tightening torques

Component		Nm
Intake manifold to cylinder head		22
Heat shield to exhaust manifold		22 1)
EGR connecting pipe to:	Mechanical exhaust gas recirculation valve	22
	Exhaust manifold	22 1)
Engine cover panel to bracket		5.5
l  1) Renew nuts.