Removing and installing intake pipe - Engine codes AEB, AJL — AUDI

AJL ANB APU
Removing

Note:

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

Observe or obtain radio code on vehicles with coded radio.
Disconnect earthing strap at battery with ignition switched off.
Remove engine cover-arrows-.
Drain coolant=> Page
19-5
.

Detach coolant hoses -1- and -3-.
Unbolt coolant expansion tank -2- (-arrows-).
Disconnect the electrical wiring to coolant level display switch -F66 on bottom of expansion tank.

Detach the throttle cable of throttle valve control unit and resistance bearing -arrows- (do not remove retainer).
Remove the air duct hose -6- from throttle valve control unit.
Detach vacuum hose -1-.
Detach vacuum line -3- to ACF container.
Pull off vacuum hose -2- for brake servo

Note:

Detach the vacuum hose -2- behind the suction jet pump in vehicles with automatic gearbox.

Pull off the following connectors:

4 -
for intake air temperature sender -G42
5 -
for throttle valve control unit -J338

Detach connector from Hall sender -G40 -arrow-.

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

Note:

Protect the removed injectors from contamination.

Detach coolant hoses from upper coolant pipe.

Unscrew coolant pipe from top of intake pipe and coolant flange -arrows- on rear of cylinder head.

Disconnect crankcase breather hose -1- from intake pipe.
Remove intake pipe support -arrows-.
Pull out oil dipstick.
Unscrew suction hose from flange 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:

Note:

Renew seals and gaskets.

Adjust throttle cable:

=> Fuel supply system - Petrol engines; Repair group 20; Servicing throttle mechanism - front and four-wheel drive
Fuel supply system - Petrol engines
Servicing throttle mechanism - front and four-wheel drive

Top up coolant => Page
19-8
.
After connecting battery, enter anti theft code for radio.

=> Radio operating instructions

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

Perform throttle-valve control part adaption:

=> Motronic injection and ignition system (4 cylinder Turbo); Repair group 24
Motronic injection and ignition system (4 cylinder Turbo)

Tightening torques

Component · Nm
Intake manifold to cylinder head · 10
Support for intake manifold · to intake manifold · 20
to retainer · 20
Fuel distributor rail to intake manifold · 10
Coolant pipe to coolant flange · 10
Coolant pipe on intake pipe · 10
Hose clamps for coolant hoses · / 2
Hose clamps for air duct hoses · / 3.5