Removing and installing intake manifold with fuel rail, cylinder bank 2 (left-side) — AUDI

🧭 Before you start

Remove the charge air cooler housing and coolant pipe, then clear vacuum hoses, secondary air valves, wiring and brackets from the manifold. Release fuel pressure, take off the high-pressure pipe and remove the manifold with rail. On refit, hold the flaps open by vacuum, press the manifold squarely onto the injectors, tighten in stages diagonally, and refit the pipe, coolant pipe and cooler housing.

Fits: Audi A8 D4 (4H, 2010–2017)

• Renewed: seals

Don't miss

• Wrap a cloth round the high-pressure connection and open it slowly; the system is pressurised.
• Do not bend the high-pressure pipe into a different shape.
• Hold the intake manifold flaps open with a hand vacuum pump while fitting the manifold.
• Renew seals and gaskets and use original-type hose clips.
• Tighten manifold bolts diagonally in stages after pressing evenly onto the injectors.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

📋 Procedure

1. Remove charge air cooler housing .
2. Remove coolant pipe (top left) .
3. Disconnect vacuum hose (3) and move clear.
4. Detach secondary air inlet valves from bracket and move clear to one side:
5. Unplug electrical connectors (4, 5) and move clear wiring harness at intake manifold.

6. Unplug electrical connector (2) for intake manifold flap potentiometer 2G512. [Note: Disregard (item 1).]
7. Remove bolt (3) and move bracket with electrical connector (2) to one side. [Note: Disregard (item 1).]
8. Detach charge pressure control solenoid valve N75(item 2) from bracket (1) and push it clear to one side.
9. Remove bolts (arrows) and push bracket towards front of vehicle.
10. Remove bolts (2).
11. ⚠ The fuel system is pressurised.Risk of injury as fuel may spray out.Wear safety goggles.Wear protective gloves.Release pressure (wrap clean cloth around connection and open connection carefully). — Wrap clean cloth around connection, remove union nuts (arrows) and press high-pressure pipe to one side. [Note: Do not attempt to bend high-pressure pipe to a different shape.Disregard (item 1).]
12. Detach noise insulation panels.
13. Remove bolts (arrows) and detach intake manifold with fuel rail. [Note: Renew seals and/or gaskets.Secure all hose connections with the correct type of hose clips (same as original equipment) Parts catalogue.]
14. ⚠ Risk of damage to intake manifold flaps.To prevent the intake manifold flaps from catching on the guide plates in the cylinder head, the flaps must be in the open position when the intake manifold is installed. — Connect hand vacuum pumpVAS 6213 to vacuum unit for actuating intake manifold flaps, as shown in illustration.
15. Use vacuum pump to generate a vacuum.
16. Press intake manifold with fuel rail evenly onto injectors.
17. Tighten bolts for intake manifold in diagonal sequence and in stages.
18. Disconnect hand vacuum pump from vacuum unit for actuating intake manifold flaps.
19. Install high-pressure pipe .
20. Install coolant pipe (top left) .
21. Install charge air cooler housing .

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