Audi Workshop Service and Repair Manuals

Removing and installing intake manifold with fuel rail After the fuel rail has been removed or renewed, intake manifold flap potentiometer -G336- must be adapted to engine control unit -J623-. Use vehicle diagnostic tester to do so. Special tools and workshop equipment required

t  Assembly tool -T10118-

t  Hose clip pliers -V.A.G 1921-

t  Socket Torx T30 -T10347- Removing –  Remove engine cover panel.   Note t  The injectors can only be accessed after the intake manifold and the fuel rail with the air flow control flaps have been removed. t  The combustion chamber (teflon) ring seal and the O-ring must always be renewed. t  Intake manifold - exploded view → Chapter t  Fuel rail - exploded view → Chapter   WARNING The fuel system is pressurised. The fuel pressure in the high-pressure part of the injection system must be reduced to a residual pressure prior to opening; for procedure see → Chapter. –  Disconnect negative terminal from battery. –  Clean joint between intake manifold and cylinder head.

–  Pull cover off air duct (release clips on sides) -arrows-. –  Unclip air duct at the bottom by releasing clips -arrows-.

–  Detach air duct at bottom together with air hose.

–  Unplug electrical connector -1- from air mass meter -G70-. –  Release hose clip -2-. –  Unscrew bolt -4- and remove air cleaner housing with air intake hose.   Note Disregard item -3-.

–  Disconnect vacuum line -arrow- leading to activated charcoal filter. –  Unplug following electrical connectors: 1 -  Intake air temperature sender -G42- 2 -  Activated charcoal filter solenoid valve 1 -N80- 3 -  Throttle valve module -J338-

Unplug electrical connector -1- at Hall sender -G40-.

–  Release fasteners -1 and 2- and remove noise insulation.

–  Release hose clips -2- on air pipe. –  Unplug electrical connector -arrow-. –  Unscrew bolts -1 and 4- and remove air hose from throttle valve module -J338- downwards. –  Pull out air hose.

–  Disconnect vacuum line -1- at position marked -2- and remove crankcase breather hose -3-.

–  Disconnect fuel supply hose -2- by pressing release ring.   Note t  The fuel system must not be under pressure. t  Use a clean cloth to catch escaping fuel.

–  Release spring-type clip -top arrow- and detach fuel supply hose from high-pressure pump. –  Unscrew union nut for high-pressure fuel pipe -bottom arrow- at high-pressure pump.   Note Seal off open connections with clean caps. It is essential to ensure that no dirt enters the fuel system.

–  Disconnect vacuum line -arrow- at intake manifold flap valve -N316-.

–  Remove two bolts -arrows- for coolant line from intake manifold.

–  Unplug electrical connector at fuel pressure sender -G247--1-.

–  Unplug electrical connectors -1- and -3- and detach connectors from retainer towards one side.

–  Slightly loosen securing nut -1- and remove bolt -2-.

–  Loosen oil filter with Hazet strap wrench -2171-1- or with oil filter tool -3417- and remove oil filter.

–  Open cable retainer -arrow- and move wiring clear. –  Unscrew bolts from intake manifold using socket Torx T30 -T10347-.   Note To remove the bolts that cannot be accessed if you do not have socket Torx T30 -T10347-, the throttle valve module -J338- must be removed. –  Carefully pull intake manifold and fuel rail slightly away from cylinder head.

–  Unplug electrical connector -1- from intake manifold flap potentiometer -G336- and then detach intake manifold.   Note t  The injectors can remain in the fuel rail. t  Block off intake ports with a clean cloth. –  Disconnect intake manifold from fuel rail → Chapter. Installing –  Fit intake manifold onto studs (left and right) on cylinder head.   Note Make sure that injectors are installed correctly. –  The remaining installation steps are carried out in the reverse sequence. l  Tightening torque: intake manifold - exploded view → Chapter l  Tightening torque: fuel rail - exploded view → Chapter