Audi Workshop Service and Repair Manuals

Removing and installing intake manifold (bottom section) with fuel rail

Special tools and workshop equipment required

t	Socket, 14 mm -3150-

t	Torque wrench -V.A.G 1331-

t	Ratchet -V.A.G 1331/1-

t	Tool insert (open-end ring spanner, 17 mm) -V.A.G 1331/2-

t	Socket insert AF 14, flared ring spanner -V.A.G 1331/8-

t	Socket -T40055-

t  Hand-operated vacuum pump -VAS 6213- Removing   Note The following description shows the removal and installation of the left-side intake manifold (bottom section). The procedure for the other side is identical.   WARNING t  The fuel system operates under high pressure. The pressure in the high-pressure part of the injection system must be reduced to a residual pressure prior to opening the system → Chapter. t  A clean cloth must then be wrapped around the connection and the residual pressure dissipated by carefully loosening the connection. –  Remove intake manifold (top section) → Chapter.

–  Remove high-pressure pipe by unscrewing bolts and union nuts -1 … 7-.

–  Unplug electrical connectors: 1 -  Intake manifold flap potentiometer 2 -G512- 2 -  Fuel pressure sender -G247- –  Unscrew bolts and nuts -arrows- and detach intake manifold (bottom section) with fuel rail.   Note Seal intake ports on cylinder heads with clean cloths. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets, seals and O-rings. t  Lightly lubricate O-rings for injectors with clean engine oil.

–  Connect hand-operated vacuum pump -VAS 6213- to vacuum unit for actuating intake manifold flaps as shown in illustration. –  Use hand-operated vacuum pump to generate vacuum. l  This will cause the intake manifold flaps to open.   Note If the intake manifold flaps are not opened, they can catch on the guide plates in the cylinder head when the intake manifold (bottom section) is installed.

–  Install intake manifold (bottom section) and press fuel rail evenly down onto injectors. –  Tighten bolts -arrows- for intake manifold (bottom section) in diagonal sequence and in stages. –  Disconnect hand-operated vacuum pump from vacuum unit for actuating intake manifold flaps. –  Plug in electrical connectors -1- and -2-.

–  First hand-tighten union nuts -1-, -4- and -7- for high-pressure pipes, then hand-tighten pipe mountings -2-, -3-, -5- and -6-. –  Ensure that high-pressure pipes are not under tension.

–  To tighten union of high-pressure pipe (14 mm) at fuel rail, use torque wrench -V.A.G 1331- with socket insert AF 14, flared ring spanner -V.A.G 1331/8-.

–  To tighten union of high-pressure pipe (17 mm) at fuel rail, use torque wrench -V.A.G 1331- with tool insert (open-end ring spanner, 17 mm) -V.A.G 1331/2-.

–  To tighten union of high-pressure pipe (14 mm) at high-pressure pump, use torque wrench -V.A.G 1331- with ratchet -V.A.G 1331/1- and socket, 14 mm -3150-.

–  To tighten union of high-pressure pipe (17 mm) at high-pressure pump, use torque wrench -V.A.G 1331- with ratchet -V.A.G 1331/1- and socket -T40055-. Tightening torques

Component		Nm
Intake manifold (bottom section) to cylinder head		9
High-pressure pipes to:	High-pressure pump	25
	Fuel rail	25