Audi Workshop Service and Repair Manuals

Removing and installing intake manifold with fuel rail After the intake manifold has been removed or renewed, intake manifold flap potentiometer -G336- (item 10) must be adapted to the engine control unit -J623-, see vehicle diagnostic and service information system -VAS 5052 A-, “Guided Function”   Caution The fuel pressure must be reduced prior to opening any components in the high-pressure section of the fuel system. It is very important to observe the procedure specified in → Chapter.   Note t  The injectors can only be accessed after removal of the intake manifold and fuel rail with air flow control flap. (Additional or fewer steps may be required depending on the model.) t  The combustion chamber (teflon) ring seal and the O-ring must always be renewed. t  After the fuel rail has been removed or renewed, intake manifold flap potentiometer -G336- must be adapted to the engine control unit -J623-, see vehicle diagnostic and service information system -VAS 5052 A-, “Guided Function”. t  Intake manifold - exploded view → Chapter Special tools and workshop equipment required

t  Assembly tool -T10118-

t  Hose clip pliers -V.A.G 1921-

t  Socket -T10347- Removing –  Remove engine cover panel → Chapter. –  Unplug all electrical connectors as necessary. –  Disconnect vacuum hose between intake manifold and vacuum pump at intake manifold.   Note This vacuum hose and the vacuum pump (located at rear of cylinder head) are only fitted on vehicles with automatic gearbox.

–  Disconnect fuel line -arrow- (catch escaping fuel and seal off open connections immediately).

–  Disconnect hose connections -arrows- at cylinder head cover.

–  Remove two bolts -1 and 2- from coolant pipe.

–  Unscrew bolts from oil pipe -1- and coolant pipe -2-.

–  Open both fuel line connections at high-pressure pump. –  Release hose clips and disconnect intake hose at throttle valve module -J338- and intake manifold.

–  Unplug electrical connector -1- at fuel pressure sender -G247-.

–  Pull out oil dipstick and unscrew bolt -2- at dipstick guide tube.

–  Unscrew bolt -1- securing oil pipe.

–  Unscrew securing nut -arrow- on intake manifold support (remove throttle valve module -J338- if necessary).

–  Disconnect oil dipstick guide at joint -2- and unscrew bolt -1- on intake manifold support. –  Unscrew bolts from intake manifold using socket -T10347-.   Note To remove the bolts that cannot be accessed if you do not have socket -T10347-, the throttle valve module -J338- must be removed. –  Carefully pull intake manifold and fuel rail off cylinder head.   Note The injectors can remain in the fuel rail. –  Removing and installing fuel rail → Chapter Installing –  Install in reverse order.

Tightening torque	Nm
Securing bolts for intake manifold	9
Bolt for intake manifold support	23
Nut for intake manifold support	10
Fuel supply pipe to high-pressure pump	30
Fuel return pipe to high-pressure pump (renew)	25
Bolts for intake manifold flap motor -V157-	7