Audi Workshop Service and Repair Manuals

Removing and installing intake manifold Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331-

t  Ratchet -V.A.G 1331/1-

t  Pliers -3314- 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.

–  Remove noise insulation -1- → Rep. gr.50.   Caution Make sure that no wire connection is damaged when unplugging the connectors; otherwise the entire wiring harness must be renewed. When unplugging the connectors, do not compress the pliers -3314- with too much force so that the support sleeve is not damaged.

–  Open catches -arrows- on cable duct to move clear wiring harness.

–  Apply groove -arrow A- of pliers -3314- to collar of support sleeve -arrow B-.

–  Carefully unplug connectors from glow plugs in direction of -arrow-.

–  Pull exhaust gas recirculation cooler changeover valve -N345--left arrow- off bracket and move clear to one side.

–  Unscrew securing bolts -arrows- and move coolant return line clear to one side.

–  Unscrew securing bolts -arrows- and move fuel return line clear to one side.   Note

–  Unplug connector -arrow- at intake manifold flap motor -V157-. –  Remove fuel rail → Chapter.

–  Unplug connector -2- from throttle valve module -J338-. –  Open clamp -1- at connecting pipe for exhaust gas recirculation and remove connecting pipe. –  Remove bolt from mounting for oil dipstick tube.

–  Open clamp -2- on air pipe. –  Remove charge air hose between throttle valve module -J338- and air pipe. To do so, unscrew bolts -arrows-. –  Remove bolts securing intake manifold in diagonal sequence starting from outside and working inwards. –  Carefully take out intake manifold. Installing Installation is carried out in the reverse order; note the following: –  Renew seals and/or gaskets. –  Tighten bolts securing intake manifold in diagonal sequence starting from outside and working inwards. –  Install fuel rail → Chapter. t  Tightening torque for intake manifold: Intake manifold with attached components - exploded view → Item. –  Install air pipe: Charge air cooler - exploded view → Rep. gr.21.

Installing air hoses with plug-in connectors   Note t  Renew seal if damaged. t  Make sure that the seal is correctly seated in the groove on the complete circumference of the air pipe/hose. t  Apply a thin coating of silicon-free lubricant to the sealing area and the seal. –  Release retaining clip (position -1-). –  Push air pipe/hose in as far as stop and press retaining clip to lock -2-. –  Press air pipe/hose again and pull again to check that plug-in connector is correctly engaged. –  Install noise insulation → Rep. gr.50.