Removing and installing intake manifold (with change-over function) — AUDI

Removing

Note:

All cable ties which are released or cut open when removing must be fitted in the same position when installing.

Obtain radio code on vehicles with coded radio.
With ignition switched off disconnect battery earth strap.
Drain cooling system=> Page
19-4
Remove engine cover.

Disconnect hose -1- going to upper coolant pipe.
Unbolt coolant expansion tank -2- (-arrows-).
Disconnect wire for coolant shortage indicator switch -F66 and move coolant expansion tank to one side.

Note:

Do not disconnect coolant hose -3-.

Disconnect air intake hose at intake pipe connection and air mass meter -arrows-.

Pull connector off Hall sender -G40 -arrow-.

Unscrew retaining bolts for fuel distributor rail and pull vacuum line off fuel pressure regulator -arrows-.
Pull fuel distributor rail together with injectors off intake manifold and place it on a clean cloth at the back of the engine compartment.

Vehicles with cruise control system

Disengage actuator rod at throttle valve control part.
Pull vacuum hose off vacuum unit.

All models

Detach throttle cable at the throttle valve control part and at support bracket -arrows- (do not remove securing clip). Move throttle cable clear to the side.

Disconnect vacuum hose -1- for ACF valve.
Disconnect hoses -arrows-.
Unclip bracket -2- for vacuum booster at coolant pipe and remove vacuum booster together with hoses.

Detach air intake elbow -arrows- and remove.

Note:

Remove the air intake elbow before removing the lower hose.

Detach two coolant hoses for heat exchanger at engine (release retaining clamps on connecting flanges).

Detach coolant hoses from upper coolant pipe.
Unbolt upper coolant pipe from intake manifold and coolant flange -arrows- at back of cylinder head.
Release cable ties for wiring harness.
Lift out coolant pipe.
Disconnect coolant hose from throttle assembly.
Disconnect connector -1- on throttle valve control part -J338.
Move wiring clear.

Disconnect wires/unplug connectors as follows:

1 -
intake air temperature sender -G42
2 -
Intake manifold change-over valve -N156

Unbolt intake manifold from the two bottom supports -arrows-.

Unbolt intake manifold from cylinder head -arrows- and remove.

Note:

Plug intake ports on cylinder head with clean cloths.

Installing

Installation is carried out in the reverse order, when doing this note the following:

Notes:

Renew seals and gaskets.
Note installation position of gasket for intake manifold.

Adjust throttle cable

=> Fuel supply system - Petrol engines; Repair group 20; Servicing accelerator mechanism; Adjusting throttle cable
Fuel supply system - Petrol engines
Servicing accelerator mechanism
Adjusting throttle cable

Fill cooling system => Page
19-6
After connecting battery, enter anti-theft code for radio

=> Radio operating instructions

Close windows fully using electric window switches.
Then operate all electric window switches again for at least one second in the "close" direction to activate the automatic one-touch function.
Set clock to correct time.

Perform adaption of throttle valve control part:

=> Motronic injection and ignition system (4-cylinder); Repair group 24; Testing throttle valve control part; Adaption of throttle valve control part to engine control unit
Motronic injection and ignition system (4-cylinder)
Testing throttle valve control part
Adaption of throttle valve control part to engine control unit

Tightening torques

Component · Nm
Intake manifold to cylinder head · 10
Support for intake manifold · to intake manifold · 25
to bracket · 20
to engine · 20
Fuel distributor rail to intake manifold · 10
Coolant pipe to coolant flange · 10
Coolant pipe to intake manifold · 10