Audi Workshop Service and Repair Manuals

Removing and installing intake manifold (top section) Special tools and workshop equipment required

t  CLIC hose clip pliers -V.A.G 1723-

t  Hose clip pliers -V.A.G 1921-

Removing   Caution Observe notes on procedure for disconnecting the battery → Electrical system; Rep. Gr.27. –  Disconnect earth wire at battery with ignition switched off. –  Lift off engine cover -arrows-.

–  If fitted, detach cover -1- on right of engine compartment.

–  Detach vent hose -2- leading to exhaust gas recirculation valve -N18-. –  Disconnect hose -4- for crankcase breather system at air pipe. –  Remove air pipe -1- and -3-.

–  Unbolt coolant expansion tank -arrow-. –  Unplug electrical wire for coolant shortage indicator switch -F66- at bottom of expansion tank and move expansion tank to one side with coolant hoses -1- and -2- attached.

–  Disconnect crankcase breather hose at connection -1-. –  Detach vacuum hose -2- leading to brake servo at bulkhead.

–  Unbolt throttle valve housing at intake manifold -arrows-.   Note Illustration shows engine removed.

–  Unplug electrical connector -1-. –  Unscrew nuts -arrows-.   Note Disregard -items 2 ... 4-.

–  Unscrew securing bolts for fuel rail -arrows-. –  Pull fuel rail off intake manifold together with injectors and set it down on a clean cloth at rear of engine compartment.   Note Disregard -items 1 ... 3-.

–  Unscrew coolant pipe (top) -arrows-.   Note Disregard -item 1-.

–  Loosen the clips at the connections -arrows-. To do this, use CLIC hose clip pliers -V.A.G 1723-. –  Pull out oil dipstick. –  Remove top section of intake manifold.   Note Block off the intake ports of the intake manifold (lower section) with clean cloths. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets and seals. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue.

–  Insert top section of intake manifold into connecting hoses and secure clips -arrows- using CLIC hose clip pliers -V.A.G 1723-. –  Observe notes on procedures required after connecting battery → Electrical system; Rep. Gr.27. Tightening torques

Component		Nm
Intake manifold (top section) to support		20
Support for intake manifold (top section) to engine		20
Throttle valve module to intake manifold (top section)		10
Fuel rail to intake manifold (top section)		10
Coolant pipe to intake manifold (top section)		10