Audi Workshop Service and Repair Manuals

Removing and installing intake manifold Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331-

t  Ratchet -V.A.G 1331/1-

t  Open end spanner insert, AF 17 -V.A.G 1331/6-

t  Socket -T40055-

t  Pliers -3314-

t  Bit XZN 8 -T40159- for vehicles with aluminium intake manifold

t  Socket T30 -T10405- for vehicles with plastic intake manifold Removing   WARNING t  Always read rules for cleanliness and instructions for working on fuel system → Chapter. t  Follow these instructions and rules for cleanliness before starting work and while working on the fuel system. –  Remove engine cover panel → Chapter. –  Take noise insulation off cylinder head cover.

–  Unplug electrical connectors -5, 6, 7 and 8- at glow plugs.   Caution Make sure that no wire connection is damaged when unplugging the connectors; otherwise the entire wiring harness must be renewed. When unplugging the connectors, do not compress the pliers -3314- with too much force so that the support sleeve is not damaged.

–  Apply groove -arrow A- of pliers -3314- to collar of support sleeve -arrow B- and pull connectors off glow plugs.

–  Unscrew union nuts at high-pressure pump -1- and fuel rail -5- and remove high-pressure fuel pipe -4-. –  Remove bolts -arrows- for high-pressure fuel pipe. –  Move wiring harness -6- clear.

–  Pull fuel pipe connections -2 and 3- off high-pressure pump.

–  Remove bolts -arrows- securing the two fuel pipes.   Note Do not bend fuel lines.   Caution t  Observe rules for cleanliness when working on the injection system. t  Plug open connections with suitable sealing caps immediately.

–  Unplug following electrical connectors: 1 -  Fuel pressure sender -G247- 2 -  Fuel pressure regulating valve -N276- 3 -  Variable intake manifold motor -V183- 4 -  Intake manifold flap motor -V157- 5 -  Exhaust gas recirculation valve -N18-

–  Open hose clip -arrow- securing air hose and disconnect hose downwards from intake manifold flap motor -V157-. –  Remove bolt on bracket for oil dipstick. –  Detach connecting pipe for exhaust gas recirculation from exhaust gas recirculation valve -N18-. –  Remove bolts securing intake manifold in diagonal sequence starting from outside and working inwards. –  Remove intake manifold. Installing Installation is carried out in the reverse order; note the following: –  Renew seals and/or gaskets. –  Tighten bolts securing intake manifold in diagonal sequence starting from outside and working inwards. l  Tightening torque: intake manifold - exploded view → Item l  Tightening torque for connecting pipe for exhaust gas recirculation: refer to exploded view of intake manifold → Chapter „Intake manifold - exploded view“ l  Tightening torque for high-pressure pipes: refer to exploded view of fuel system → Chapter