Audi Workshop Service and Repair Manuals

Removing and installing intake manifold (left-side) Special tools and workshop equipment required

t  Ring spanner -3035- t  Torque wrench -V.A.G 1331- with 17 mm attachment (commercially available)

t  Open ring spanner or open-end spanner Removing   Note All cable ties which are released or cut open when removing must be fitted in the same position when installing. –  Remove intake manifold (front section): t  Vehicles with engine code letters AKE, AYM, BAU, BCZ, BFC → Chapter. t  Vehicles with engine code letters BDG, BDH → Chapter.

–  Disconnect vacuum hose at mechanical exhaust gas recirculation valve -arrow-.

–  Remove heat shield above turbocharger -arrows-. –  Mark position of retaining clips on injector pipes (e.g. with felt-tip pen). –  Mark injector pipes according to cylinder (e.g. with felt-tip pen). –  Disconnect injector pipes one by one with ring spanner -3035-. –  Move wiring harness near intake manifold (left-side) clear to the side.

–  Remove intake manifold (left-side) -arrows-. –  Watch the two dowel sleeves when removing intake manifold. –  Block off intake ports in cylinder head with clean rags. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets and seals. t  Fit all cable ties in the original positions when installing. –  Watch the two dowel sleeves when installing intake manifold. –  Fit injector pipes one at a time, working from bottom to top and secure using torque wrench -V.A.G 1331- and 17 mm attachment (commercially available).   Note t  Ensure stress-free installation of injector pipes. t  The injector pipes must always be re-installed on the same cylinder. t  Make sure that retaining clips are positioned correctly. –  Install intake manifold (front section): t  Vehicles with engine code letters AKE, AYM, BAU, BCZ, BFC → Chapter. t  Vehicles with engine code letters BDG, BDH → Chapter. Tightening torques

Component		Nm
Intake manifold (left-side) to cylinder head		10
Mechanical EGR valve to intake manifold (left-side)		22
EGR pipe to intermediate flange		22
Injector pipes to:	Injectors	30
	Injection pump	30
Heat shield to turbocharger		10