Removing and installing intake manifold (left and right bottom sections) - vehicles up to 10.2004 — AUDI

🧭 Before you start

Fits: Audi A8 D3 (4E, 2002–2010)

• Renewed: seals

Don't miss

• Disregard (items 1, 3, 4).
• Block off intake ports in cylinder head with clean rags.
• The return lines can only be renewed together with the pressure retention valve as one unit.
• If there is any air left in the fuel system, the engine may switch to the backup mode ('emergency running' mode) during the road test. Switch off the engine and erase the fault memory. Then continue the road test.

🔧 Engine codes this applies to

📐 20 workshop diagrams for ASB

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Pull off engine cover (see the separate procedure).
2. ⚠ Observe rules for cleanliness when working on the injection system (see the separate procedure). — Unscrew union nuts (arrows) and detach high-pressure pipes.
3. Remove intake manifold (top section) (see the separate procedure).
4. Unscrew retaining pin (2) for engine cover panel at intake manifold (bottom section).
5. If fitted, remove change-over valve for exhaust gas recirculation cooler N345(item 1) with bracket.

6. Take electrical connector (arrow) for exhaust gas temperature sender 1G235 out of bracket.
7. Remove bolt (2). [Note: Disregard (items 1, 3, 4).]
8. Detach electrical connectors at glow plugs on cylinder bank (right-side).
9. Detach electrical connector (1) at intake manifold flap motor.
10. Remove bolts (arrows) and detach intake manifold (bottom section) with intake manifold flap motor. [Note: Block off intake ports in cylinder head with clean rags.] [Note: Renew seals and gaskets. Fit all cable ties in the original positions when installing.]
11. Install intake manifold (top section) (see the separate procedure).
12. To tighten union of high-pressure pipe at high-pressure pump, use torque wrench V.A.G 1331 with socket insert AF 14, flared ring spanner V.A.G 1331/8.
13. To tighten unions of high-pressure pipes at rail elements, use torque wrench V.A.G 1331 with ratchet V.A.G 1331/1 and socket, 14 mm 3150.
14. Check fuel system for leaks.
15. Run engine at idling speed for several minutes and then switch off.
16. Switch off ignition.
17. Check the complete fuel system including all 6 return line connections for leaks. [Note: The return lines can only be renewed together with the pressure retention valve as one unit.]
18. After completing the repair, road-test the vehicle over a distance of at least 20 km. Accelerate with full throttle at least once. Then inspect the high-pressure section of the fuel system again for leaks. [Note: If there is any air left in the fuel system, the engine may switch to the backup mode ('emergency running' mode) during the road test. Switch off the engine and erase the fault memory. Then continue the road test.]

Other AUDI procedures

• Removing cylinder head - vehicles up to 08.2005 – Audi ASB
• Removing cylinder head - vehicles from 08.2005 onwards
• Removing and installing high-pressure pump - vehicles from 09.2005 onwards
• Checking fuel gauge sender 2G169 – Audi Q7
• Removing and installing bottom section of intake manifold (right-side) - vehicles from 08.2004 onwards
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