Removing and installing intake pipe - Engine codes ANB, APU — 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-).
Detach the electrical wiring to coolant level display switch -F66 on bottom of expansion tank.

Unplug vacuum hoses -1 ... 3-.
Disconnect wires/unplug connectors as follows:

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

Detach the air duct hose -6- from throttle valve control unit.

Unscrew retaining plate for recirculation valve for turbocharger -N249 -1- from underneath intake pipe and secondary air inlet valve -N112 -2- -arrows-.

Notes:

The electrical connectors and vacuum hoses do not have to be disconnected.
The secondary inlet valve is only installed in vehicles with engine code ANB.

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.

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.

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