Audi Workshop Service and Repair Manuals

Removing and installing intake manifold Removing

–  Lift off engine cover panel (outside -1- and inside -2-) by pulling up evenly.

–  Unclip fuel and coolant hoses from air intake pipe (right-side). –  Remove retaining bolt -1-. –  Remove air pipe (right-side) by lifting retaining clips -arrows- slightly.

–  Detach electrical connector -1- at intake manifold flap motor -V157-. –  Remove bolts -arrows- and detach intake manifold flap motor -V157-.

–  Unplug electrical connector -1- at exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer -G212-. –  Move electrical wiring harness clear. –  Remove bolts -arrows-. –  Detach exhaust gas recirculation valve -N18- at intake manifold.   Note Shown from rear with engine removed for illustration purposes.

–  Unplug electrical connector -4- for Lambda probe -G39-.

–  Unscrew Lambda probe -3-. –  Remove temperature sender before particulate filter -G506--item 5-. –  Unbolt bracket -2- for pressure pipes. –  Detach pressure pipe -4- at particulate filter. –  Slacken retaining clamp -1- for particulate filter. –  Detach retaining clamp.

–  Remove front right wheel. –  Remove centre noise insulation -fasteners 1 ... 3-.

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

–  Unscrew temperature sender after particulate filter -G527--item 1- from exhaust pipe behind particulate filter. –  Unscrew pressure pipe -2- going to exhaust gas pressure sensor 1 -G450-.   Note The threaded connections are accessible through the wheel housing (right-side).

–  Unplug electrical connector -arrow- at exhaust gas pressure sensor 1 -G450-. –  Unscrew exhaust gas pressure sensor 1 -G450- and detach together with pressure pipes.

–  Unbolt heat shield for drive shaft (right-side) -arrows-. –  Unbolt drive shaft (right-side) from gearbox flange. –  Push drive shaft (right-side) towards front of vehicle.

–  Unscrew bolts -1 ... 3- and remove pendulum support.

–  Remove bolts -arrows- on bracket for particulate filter.

–  Remove front cross-piece for underbody -arrows-.   Note To avoid damage, the flexible joints in the front exhaust pipe must not be bent more than 10°. –  Loosen nuts on clamp -1-.

–  Unbolt bracket for exhaust system -arrows-. –  Take out particulate filter: turn it 180° clockwise and at the same time push engine/gearbox assembly slightly forwards.

–  Unbolt connecting pipe going to exhaust gas recirculation cooler -arrows-.

–  Remove nuts -1-, bolt -2- and banjo bolt -3-. –  Remove support for turbocharger together with oil return pipe.

–  Unbolt heat shield on exhaust manifold (left-side) -arrows-.

–  Unscrew bolts -arrows- on flange between exhaust gas recirculation cooler and intake manifold.

–  Remove bolts -arrows-. –  Remove intake manifold (lift out towards right side). Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets and seals. t  Note the installation position of intake manifold gasket. 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 particulate filter and front exhaust pipe → Rep. Gr.26. –  Align exhaust system so it is free of stress → Rep. Gr.26. –  Install front cross-piece for underbody → Rep. Gr.66.

–  When installing air pipes with plug-in connectors, ensure that the securing clip -arrow- engages audibly on the retaining lug -A-. Tightening torques

Component		Nm
Intake manifold to cylinder head		22
Exhaust gas recirculation cooler to intake manifold		22
Heat shield to exhaust manifold		25
Support for turbocharger to:	Cylinder block	60
	Turbocharger	25
Oil pipe to turbocharger		15
Pendulum support to:	Gearbox	40 + 90° 1)2)
	Subframe	100 + 90° 1)2)
Drive shaft heat shield to cylinder block		35
Exhaust gas recirculation valve -N18- to intake manifold		10
Intake manifold flap motor -V157- to intake manifold		10
Air pipe to bracket		10
t  1) Renew bolts. t  2) 90° = one quarter turn.