Intake Manifold, Removing and Installing

Intake manifold, removing and installing

CAUTION: Before beginning repairs on the electrical system:
^ Obtain the anti-theft radio security code.
^ Switch the ignition off.
^ Disconnect the battery Ground (GND) strap.
^ On vehicles equipped with Audi Telematics by OnStar, switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery.
^ After reconnecting vehicle battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows.
^ After reconnecting vehicle battery on vehicles equipped with Audi Telematics by OnStar, switch-on the emergency (back-up) battery for the Telematic/Telephone Control Module.

Removing

Note: All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

- Drain coolant.

WARNING: Observe safety precautions when disconnecting the battery.

See Caution before beginning repairs on the electrical system

- Switch ignition off and disconnect battery Ground (GND) strap.





- Remove rear engine cover (arrows).





- Remove front engine cover (arrows).





- Remove cover -1- in engine compartment (right side).





- Remove bolts (arrows).
- Detach Evaporative Emission (EVAP) canister purge regulator valve -N80- -1- at air guide.
- Remove air guide -2-.





- Remove air filter housing (arrows).
- Disconnect electrical harness connector -1- at Mass Air Flow (MAF) sensor.
- Remove air guide hose -2- together with Mass Air Flow (MAF) sensor.





- Disconnect vacuum hoses -2- and -3- at Intake manifold change-over valve -N156-.
- Disconnect vacuum hose -6- from check valve.
- Disconnect electrical harness connector -5-.
- Set aside hose of crankshaft housing ventilation (arrow).
- Remove bolts -1-, -4- and -7- for holding plate for solenoid valves.
- Remove holding plate for solenoid valves.





- Disconnect electrical harness connector -1-.
- Pull off vacuum hose -2- at T-connector.
- Remove all harness connectors to injectors.





- Disconnect vacuum line at fuel pressure regulator and remove mounting bolts of fuel pressure regulator (arrows).
- Remove fuel distributor together with fuel injectors from intake manifold simultaneously upward and place it on a clean rag in engine compartment.

Note: Carefully protect removed fuel injectors from contamination.





- Disconnect electrical harness connector -1- at Throttle valve control module -J338-.
- Disconnect vacuum hoses -2- and -3-.





- Disconnect hose -1- from air duct.
- Remove bolt -4- and disconnect air duct -2- at throttle valve control module.
- If installed, disconnect vacuum hose -3- from air guide at bottom.





- Disconnect vacuum line (arrow) to leak detection pump at throttle valve control module.





- Remove bolts -1- and -3-.
- Pull out guide tube for oil dipstick 2 from the oil pan (upper part) toward top and swing it forward for removal.

Note: Hose -4- remains connected.





- Remove bolts at right side of engine (arrows) at line for secondary air injection.





- Remove bolts -1- and -2- at lines of secondary air injection.
- Remove bolts -3- and -5- and remove resonator -4-.





- Disconnect vacuum hose -1- at EVAP valve.
- Remove coolant hoses -2- and -3-.





- Unbolt intake pipe (arrows) and remove.

Note: Plug intake channels in the cylinder heads with clean rags.

Installing
Installation is reverse of removal, noting the following:

Note:
^ Secure all hose connections using hose clamps appropriate for the model type:
^ Always replace seals and gaskets.





- Bolt in intake manifold in diagonal sequence in stages (arrows).
- Replace O-ring at guide tube for oil dipstick and insert guide tube into hole in oil pan (upper part).

See Caution for connecting Telematics battery

- Observe safety precautions after connecting battery.
- Top off coolant.

Tightening torques