Audi Workshop Service and Repair Manuals > A4 Mk2 > Power unit | TDI injection and glow plug system (6-cyl.) | Fuel preparation system Diesel injection | Servicing diesel direct injection system | Removing and installing intake manifold (right-side)

Removing and installing intake manifold (right-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 hoses -arrows- from turbocharger and mechanical exhaust gas recirculation valve.

–	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 and fuel pipes near intake manifold (right-side) clear to the side.

–	Remove intake manifold (right-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 (right-side) to cylinder head		10
Oil pipe to intake manifold		22
Injector pipes to:	Injectors	30
	Injection pump	30

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