Audi Workshop Service and Repair Manuals

Removing and installing intake manifold Removing   Note All cable ties which are released or cut open when removing must be fitted in the same position when installing. –  Drain off coolant → Chapter.   Caution Observe notes on procedure for disconnecting the battery → Rep. Gr.27. –  Disconnect earth wire at battery with ignition switched off.

–  Pull off engine cover panel (rear) -arrows-.

–  Pull off engine cover panel (front) -arrows-.

–  Remove cover -1- at right of engine compartment.

–  Remove bolts -arrows-. –  Disengage activated charcoal filter solenoid valve 1 -N80--item 1- at air duct. –  Remove air duct -2-.

–  Remove air cleaner housing -arrows-. –  Unplug electrical connector -1- at air mass meter -G70-. –  Remove air intake hose -2- with air mass meter -G70-.

–  Disconnect vacuum hoses -2- and -3- at intake manifold change-over valve -N156-. –  Disconnect vacuum hose -6- from non-return valve. –  Unplug electrical connector -5-. –  Move the crankcase breather hose -arrow- clear. –  Unscrew bolts -1-, -4- and -7- and remove retaining plate for solenoid valves.

–  Unplug electrical connector -1- at intake manifold change-over valve -N156-. –  Disconnect vacuum hose -2- from T piece. –  Unplug electrical connectors at all injectors.

–  Disconnect vacuum hose at fuel pressure regulator (only on vehicles with fuel return pipe) and unscrew bolts on fuel rail -arrows-. –  Pull fuel rail together with injectors off intake manifold (pull off evenly from the top) and place it on a clean cloth in the engine compartment.   Note Make sure the removed injectors do not become soiled.

–  Unplug electrical connector -1- at throttle valve module -J338-. –  Disconnect vacuum hoses -2- and -3-.

–  Disconnect hose -1- from air duct. –  Unscrew bolt -4- and pull air duct -2- off throttle valve module -J338-. –  If fitted, pull vacuum hose -3- off at lower part of air duct.

USA models: –  Disconnect vacuum hose leading to fuel system diagnostic pump -V144- from throttle valve module -J338-.

All models: –  Remove bolts -1- and -3-. –  Pull guide tube -2- for oil dipstick upwards out of top section of sump and fold forwards.   Note Leave hose -item 4- connected.

–  On right side of engine, unscrew and remove bolts -arrows- at secondary air pipe.

–  Unscrew bolts -1- and -2- at secondary air pipes. –  Unscrew bolts -3- and -5- and remove resonator -4-.

–  Disconnect vacuum hose -1- leading to solenoid valve 1 for activated charcoal filter system -N80-. –  Detach coolant hoses -2- and -3-.

–  Remove bolts -arrows-. –  Remove intake manifold.   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 and seals. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. t  Adhere to the instructions for installing the fuel rail → Rep. Gr.24. –  Tighten bolts -arrows- for intake manifold in diagonal sequence and in stages. –  Renew O-ring on guide tube for oil dipstick and insert guide tube into hole in top section of sump. –  Observe notes on procedures required after connecting battery → Rep. Gr.27. –  Fill cooling system → Anchor. Tightening torques

Component		Nm
Intake manifold to cylinder head		10
Resonator to coolant pipe / to cylinder head		10
Secondary air pipe to cylinder head	M6	10
	M8	23
Secondary air pipe to combination valve for secondary air system		10
Air duct to intake manifold		10
Retaining plate for solenoid valves to intake manifold / air duct		10
Guide tube for oil dipstick to secondary air pipe		10