Audi Workshop Service and Repair Manuals

Removing and installing intake manifold with fuel rail After the fuel rail has been removed or renewed, intake manifold flap potentiometer -G336- must be adapted to engine control unit -J623-. Use → Vehicle diagnostic tester in „Guided Functions“ mode. Special tools and workshop equipment required

t  Assembly tool -T10118-

t  Hose clip pliers -V.A.G 1921-

t  Socket Torx T30 -T10347- Removing   Note t  The injectors can only be accessed after the intake manifold and the fuel rail with the air flow control flaps have been removed. t  The combustion chamber ring seal (teflon) and the O-ring must be renewed. t  Intake manifold - exploded view → Chapter t  Fuel rail - exploded view → Chapter   WARNING The fuel system is pressurised. The fuel pressure in the high-pressure part of the injection system must be reduced to a residual pressure prior to opening; for procedure see → Chapter. –  Disconnect negative terminal from battery. –  Remove engine cover panel → Chapter.

–  Disconnect vacuum line -arrow- leading to activated charcoal filter. –  Unplug following electrical connectors: 1 -  Activated charcoal filter solenoid valve 1 -N80- 2 -  From knock sensor 1 -G61- 3 -  From intake manifold flap valve -N316-, fuel pressure sender -G247- and Hall sender -G40- 4 -  From injectors 5 -  Throttle valve module -J338- 6 -  Intake air temperature sender -G42-

Unplug electrical connector -1- at Hall sender -G40-.

–  Open hose clip -arrow- securing air intake hose and disconnect hose downwards from throttle valve module -J338-.

–  Disconnect vacuum line -1- at connection -2-. –  Remove crankcase breather hose -3-.   Note

–  Release spring-type clip -top arrow- and detach fuel supply hose from high-pressure pump. –  Unscrew union nut for high-pressure pipe -bottom arrow- at high-pressure pump.   Note t  The fuel system must not be under pressure. t  Use a clean cloth to catch escaping fuel. t  Seal off open connections with clean caps. Make sure no dirt gets into the fuel system.

–  Disconnect vacuum line -arrow- at intake manifold flap valve -N316-.

–  Remove bolt -arrow- for coolant line from intake manifold.

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

–  Slightly loosen securing nut -1- and remove bolt -2-.

–  Loosen oil filter with Hazet strap wrench -2171-1- or with oil filter tool -3417- and remove oil filter. –  Unscrew bolts from intake manifold using socket Torx T30 -T10347-.   Note To remove the bolts that cannot be accessed if you do not have socket Torx T30 -T10347-, the throttle valve module -J338- must be removed. –  Carefully pull intake manifold and fuel rail slightly away from cylinder head.

–  Unplug electrical connector -1- from intake manifold flap potentiometer -G336- and then detach intake manifold.   Note t  The injectors can remain in the fuel rail. t  Block off intake ports with a clean cloth. –  Disconnect intake manifold from fuel rail → Chapter. Installing   Note Make sure that injectors are installed correctly. –  Fit intake manifold onto studs (left and right) on cylinder head. –  The remaining installation steps are carried out in the reverse sequence. l  Tightening torque: intake manifold - exploded view → Chapter l  Tightening torque: fuel rail - exploded view → Chapter