Audi Workshop Service and Repair Manuals

Removing and installing bottom section of intake manifold (left-side) 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. Vehicles with engine codes CAMA, CAMB, CCWA, CCWB, CGKA, CGKB, CCLA:

–  Unscrew bolts -arrows- and remove retaining clips. –  Unscrew union nuts -1 ... 4- and detach high-pressure pipes. Vehicles with engine code CAPA:

–  Unscrew union nuts -1- and -3-. –  Move high-pressure pipes clear and detach.   Note Disregard item -2-. All vehicles (continued): –  Remove top section of intake manifold → Chapter.

–  Carefully press connecting rod -2- off intake manifold flap 2 motor -V275- in direction of -arrow- (observe note).   Note Proceed carefully when pressing connecting rod off ball stud (risk of breaking). –  Unplug electrical connector -1-. –  Unscrew bolts -3- and detach intake manifold flap motor -V275--item 4-. –  Unplug electrical connectors for glow plugs on cylinders 4, 5 and 6. –  Take exhaust gas recirculation cooler change-over valve -N345--item 1- out of bracket. Vehicles with engine codes CAPA, CAMA, CAMB:

–  Use jointed wrench to unscrew banjo bolt -arrow- securing coolant bleeder pipe. Vehicles with engine codes CCWA, CCWB, CGKA, CGKB, CCLA:

–  Remove bolt -4-.

–  Release clamp -arrow- and detach exhaust gas recirculation pipe -1-. All vehicles (continued):

–  Remove bolts -arrows-. –  Press coolant bleeder pipe to one side and detach bottom section of intake manifold (left-side) to the front.   Note Block off intake ports in cylinder head with a clean rag. Installing l  Tightening torques: refer to intake manifold - exploded view → Chapter Installation is carried out in the reverse order; note the following:   Note Renew seals and gaskets. –  Before installing intake manifold (bottom section), screw in banjo bolt for coolant bleeder pipe 2 to 3 turns with new seals (only for vehicles with engine codes CAPA, CAMA, CAMB). –  Tighten banjo bolt for coolant bleeder pipe to 15.5 Nm. –  Install top section of intake manifold → Chapter. –  Install high-pressure pipes → Chapter.