Audi Workshop Service and Repair Manuals

Removing and installing intake manifold

Special tools and workshop equipment required

t	Locking pin -T10060-

t	Puller -T10095 A-

t	Assembly tool -T10118-

Removing   Note All cable ties which are released or cut open when removing must be refitted in the same position when installing.   Caution Observe notes on procedure for disconnecting the battery → Rep. Gr.27.

–  Remove the moulded insert for tools from beneath the luggage compartment floor cover. –  Unscrew the lid -arrow- of the battery compartment. –  Remove moulded insert from top of battery.

–  With ignition switched off, disconnect earth wire -arrow- at battery.

–  Remove centre noise insulation -fasteners 1 ... 3-.

–  Remove noise insulation (right-side) -fasteners 1 ... 3-.

–  Detach vacuum hose -2- from air intake hose. –  Disconnect air intake hose -1- from throttle valve module -J338-. –  Unplug electrical connector for air mass meter -G70- -item 3-. –  Unscrew air cleaner housing (upper section) -arrow-. –  Take out filter element.

–  Pull cover -1- off air duct. –  Unclip air duct -2-.

–  Unscrew air duct (lower section) -arrows-.

–  Unscrew air cleaner housing (lower section) -arrows-.

–  Disconnect secondary air hose at the position marked with an -arrow-. –  Move air hose to secondary air pump clear.

–  Unplug electrical connectors -2- and -3-. –  Remove crankcase breather hose -1-.

–  Unbolt throttle valve module -J338- from intake manifold -arrows- and move clear to one side.

–  Detach electrical connectors at ignition coils by releasing tab -arrow- with assembly tool -T10118- and carefully pulling connector.

–  Attach puller -T10095 A- to ignition coils as shown in illustration -arrow- and remove ignition coils one at a time. –  Remove retainer for ignition cable harness and move to one side.   Note

Some versions have plug-in vacuum connections on the intake manifold as illustrated. To disconnect, push back rubber cap -1- and slide back retaining tab -2-.

–  Disconnect vacuum hoses -2 ... 5- at rear of intake manifold.   Note Disregard -item 1-. –  Unbolt hose bracket from intake manifold -arrows- and move clear to rear, with hoses attached.

–  Remove rear securing bolts -arrows- for intake manifold.

–  Unscrew upper securing bolts -upper arrows- for radiator cowl. –  Pull out oil dipstick.   Note

Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage. –  To slacken poly V-belt turn tensioning element in direction of arrow. –  Lock tensioning element in position with locking pin -T10060- or with an Allen key. –  Remove poly V-belt.

–  Move coolant hose at bottom of radiator cowl clear. –  Unplug electrical connector -3- at secondary air pump motor -V101-. –  Move wire clear. –  Unscrew bracket -2- for coolant pipe. –  Remove bolts -1-. –  Loosen bolt -4- and remove secondary air pump with bracket.

–  Detach electrical connectors -1- for radiator fans at bottom of radiator cowl. –  Unscrew lower securing bolts -lower arrows- for radiator cowl. –  Remove the radiator cowl with both fans from below.

–  Unplug electrical connector -1- for magnetic clutch at AC compressor and move electrical wiring clear.   WARNING The air conditioner refrigerant circuit must not be opened. –  Unscrew bolts -arrow- for air conditioner compressor. –  Tie up air conditioner compressor together with refrigerant hoses at front of longitudinal member (refrigerant hoses remain connected).

–  Unscrew wire -1- at alternator. –  Unplug electrical connector -2-.   Note Disregard -item 3-.

–  Remove the upper idler roller -1-. –  Unscrew securing bolts -2- and -3- for alternator.   Note The alternator can only be removed from bracket with upper securing bolt still inserted. –  Remove alternator from bracket for ancillary units (electrical wires remain connected). –  Take out alternator to the bottom left.

–  Unplug electrical connector -arrow- at continued coolant circulation pump -V51-. –  Remove bolts -1 ... 5- and detach bracket for ancillaries. –  Pull the continued circulation coolant pump -V51- downwards out of the rubber retainers on bracket (with coolant hoses attached). If necessary, spray rubber retainers with silicone-free lubricant.   Note The coolant pump with attached coolant hoses can be left in place on the engine.

–  Unhook connector -arrow- for engine speed sender -G28- from bracket on guide tube for oil dipstick.

–  Unscrew bolt -3- and pull out guide tube for oil dipstick -2-. –  Unscrew bolt -4- and detach vacuum reservoir -1- from manifold. –  Move vacuum reservoir to side (hoses remain attached).

–  Unscrew bolts -arrows- at front of intake manifold.

–  Disconnect vacuum hose -arrow- at actuator for intake manifold change-over.   Note Disregard items marked -1- and -2-.

–  Protect the intake manifold from damage with a clean cloth -1-. –  Pivot intake manifold forwards -arrow 1- and then pull slightly to the left -arrow 2-.   Note Cover or plug the intake ports in the cylinder head with a clean cloth or foam plastic to prevent small items from dropping in. –  Unbolt bracket for fuel line (right-side) at cylinder head cover.

–  Move electrical wiring harness -1- on cylinder head cover clear to one side. –  Remove bolts -arrows-. –  Remove fuel rail -2- with fuel injectors from cylinder head and move clear to one side (fuel line remains attached). –  Swing intake manifold back to its fitting position and remove. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew seals and gaskets. t  To simplify assembly, detach wiring harness -1- to injectors from fuel rail. –  Install bracket for ancillary units → Rep. Gr.13 –  Install alternator → Rep. Gr.27. –  Install air conditioner compressor → Rep. Gr.87. –  Install radiator cowl → Rep. Gr.19. –  Install secondary air pump → Rep. Gr.26. –  Install poly V-belt → Rep. Gr.13. –  Connect earth strap to battery → Rep. Gr.27. Tightening torques

Component	Nm
Intake manifold to cylinder head	13
Intake manifold support to intake manifold	20
Throttle valve module -J338- to intake manifold	10
Vacuum reservoir to intake manifold	5
Guide tube for oil dipstick to intake manifold	5