Audi Workshop Service and Repair Manuals

Removing and installing bottom section of intake manifold (left-side)

Special tools and workshop equipment required

t	Torque wrench -V.A.G 1331-

t	Ratchet -V.A.G 1331/1-

t	Tool insert, AF 19 -V.A.G 1331/5- for vehicles from 09.2005 onwards

t	Socket -T40055-, 17 mm for vehicles from 09.2005 onwards

t  Socket insert AF 14, flared ring spanner -V.A.G 1331/8- for vehicles up to 09.2005

t  Socket, 14 mm -3150- for vehicles up to 09.2005 Removing   Caution 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. –  Drain off coolant → Rep. gr.19. –  Remove engine cover panel → Chapter. Vehicles up to 09.2005:

–  Unscrew union nuts -arrows- and detach high-pressure pipes. Vehicles from 09.2005 onwards:

–  Unscrew union nuts -1 ... 4- and detach high-pressure pipes. All vehicles: –  Remove intake manifold (top section) → Chapter. –  Remove mechanical exhaust gas recirculation valve → Rep. gr.26.

–  Unscrew retaining pin -2- for engine cover panel at intake manifold (bottom section). –  Unclip change-over valve for exhaust gas recirculation cooler -N345--1- from bracket. –  Remove bracket for change-over valve for exhaust gas recirculation cooler -N345-.

–  Remove banjo bolt for coolant bleeder pipe using jointed wrench as illustrated.

–  Unplug electrical connector -1- at intake manifold flap 2 motor -V275-. –  Remove bolts -arrows-. –  Push coolant bleeder pipe to one side and take out bottom section of intake manifold (left-side) together with intake manifold flap motor.   Note Block off intake ports in cylinder head with a clean rag. Installing Installation is carried out in the reverse order; note the following:   Note Renew gaskets and seals. –  Fit banjo bolt for coolant bleeder pipe with a new seal and screw in 2 … 3 turns, before installing left-side intake manifold (bottom section). –  Install mechanical exhaust gas recirculation valve  → Rep. gr.26. –  Install intake manifold (top section) → Chapter.   Note t  Note identification marks for cylinder allocation when re-installing high-pressure pipes. t  The high-pressure pipes can be re-used after performing the following checks: t  Check taper seats of high-pressure pipes for deformation and cracks. t  The bore of the pipe must not be distorted, restricted or otherwise damaged. t  Corroded pipes must not be used again. –  Lubricate threads of union nuts with fuel. –  Tighten union nuts on high-pressure pipes hand-tight initially. –  Ensure that high-pressure pipes are not under tension.

Vehicles up to 09.2005: –  To tighten union of high-pressure pipe at high-pressure pump, use torque wrench -V.A.G 1331- with socket insert AF 14, flared ring spanner -V.A.G 1331/8-.

–  To tighten unions of high-pressure pipes at rail elements, use torque wrench -V.A.G 1331- with ratchet -V.A.G 1331/1- and socket, 14 mm -3150-.

Vehicles from 09.2005 onwards: –  To tighten union of high-pressure pipe at high-pressure pump, use torque wrench -V.A.G 1331- with ratchet -V.A.G 1331/1- and socket -T40055-, 17 mm.

–  To tighten unions of high-pressure pipes at rail elements, use torque wrench -V.A.G 1331- with tool insert, AF 19 -V.A.G 1331/5-. All vehicles: –  Fill cooling system → Rep. gr.19. –  Check fuel system for leaks → Chapter. Tightening torque

Component		Nm
Intake manifold (bottom section) to cylinder head		9
High-pressure pipes		25
Banjo bolt for coolant bleeder pipe		15.5