Audi Workshop Service and Repair Manuals

Removing and installing intake manifold Special tools and workshop equipment required

t  Removal lever -80 - 200-

t  Hose clip pliers -VAS 6362-

Removing   Caution t  Use an absorbent cloth to catch escaping fuel. t  No fuel must be allowed to spill onto components or seals in the vicinity of the engine; this can ultimately lead to damage caused by leaking seals. t  Risk of malfunctions caused by dirt. t  Observe → Chapter „Safety precautions when working on the fuel system“. –  Pull off engine cover panel → Chapter. –  Use removal lever -80 - 200- to move electrical wiring harness and hoses clear at cable guide -1-. –  Pull coolant hose off to rear -arrow-. –  Unscrew bolts -2 and 3- and remove cable guide -1-.

–  Unscrew bolts -1 and 2- and detach retaining clamp -3-. –  Unscrew union nuts -arrows- and detach high-pressure pipe (top).

–  Detach electrical connectors -1 and 2- and remove non-return valve -3- from bracket.

–  If fitted, remove bolt -2- at retaining clamp for high-pressure pipe.   Note Disregard -item 1-.

–  Remove bolt -1- from bracket (right-side) for intake manifold.   Note Disregard -item 2-.

–  Unplug electrical connector -2- at coolant valve for cylinder head -N489--item 1-. –  Unscrew bolts -arrows- and place bracket with coolant valve for cylinder head -N489- to the side.

–  Unplug electrical connector -arrow- at coolant temperature sender -G62-.

–  Unplug electrical connectors -1 and 2- and move wiring harness clear to left side. –  Remove bolt -3- from bracket (centre) for intake manifold.

–  Pull out plug -3-. –  Remove bolt -2- for dipstick guide tube.   Note Disregard -item 1-.

–  Release screw-type clip -2- on exhaust gas recirculation pipe.   Note Disregard -item 1-.

–  Remove bolts -2- from bracket (left-side) for air pipe.   Note Disregard -item 1-.

–  Unplug electrical connector -1- at throttle valve module -J338-. –  Release screw-type clip -3- and detach air hose.   Note Disregard -item 2-. –  Unplug electrical connectors on glow plugs.

–  Remove fuel pressure sender -G247--arrow- → Chapter.

–  Remove bolts -1 ... 4- and -arrows- and detach intake manifold. Installing Installation is carried out in the reverse order; note the following: l  Tightening torques → Fig. „„Intake manifold - tightening torque and sequence““   Note t  Renew seals and/or gaskets. t  Hose connections and air pipes and hoses must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  To secure the air hoses at their connections, spray rust remover onto the worm thread of the used hose clips before installing. –  Tighten bolts for intake manifold → Fig.. –  Install high-pressure pipe → Chapter. –  Install dipstick guide tube → Rep. gr.17. –  Install exhaust gas recirculation pipe → Rep. gr.26.