Audi Workshop Service and Repair Manuals

Removing and installing intake manifold (top section) 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  In order to reach the injectors, first remove the intake manifold with the fuel rail. t  The combustion chamber ring seal (teflon) and the O-ring must be renewed.   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.

–  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-   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. It is essential to ensure that no dirt enters the fuel system.

–  Unscrew bolts -1 and 2- and detach bracket for electrical connectors.

–  Unplug electrical connector -2- at fuel pressure sender for low pressure -G410-. –  Unplug electrical connector -4- at Hall sender -G40-. –  Release hose clips -1- and disconnect the two fuel lines. –  Release hose clip -3-.

–  Detach line for active charcoal filter at intake manifold (top section) and at connection -arrows-. –  Detach activated charcoal filter solenoid valve 1 -N80--5- from bracket. –  Guide line coming from activated charcoal filter out underneath fuel lines and put to one side.

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

–  Unscrew union nut for high-pressure fuel line -bottom arrow- at high-pressure pump. –  Unscrew union nut and remove high-pressure fuel line from intake manifold (top section). –  Loosen union nut securing high-pressure fuel line to fuel rail.

–  Remove bolt -arrow- for coolant line from intake manifold (top section).

–  Remove bolt -2-. –  Unscrew bolts from intake manifold (top section) using socket -T10347-. –  Detach top section from bottom section of intake manifold.

–  Unplug electrical connector at cold-start valve -N17-.   Note Block off intake ports with a clean cloth. –  Remove intake manifold (bottom section) → Chapter. Installing –  Renew connecting pieces for high-pressure fuel line at high-pressure fuel pump and at fuel rail. –  Fit intake manifold onto studs (left and right) on cylinder head. –  Tighten union nuts on high-pressure fuel line hand-tight. –  Tighten intake manifold bolts to torque, working from inside to outside. –  Secure high-pressure fuel line (specified torque). –  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