Removing and installing lower section of intake manifold — AUDI

AKL APF
Auxiliary equipment required

Adhesive sealant

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Removing

Important
On vehicles with telematics, activate service mode of telematics control unit before disconnecting battery.=>Radio, Telephone and Navigation System; Repair group 91
Refer to coding on vehicles with encoded radio/radio navigation system (RNS); if necessary, interrogate.
Disconnect earth strap at battery with ignition switched off.

Vehicles with bolted engine cover:

Remove the front engine cover -arrows-.

Vehicles with clip-on engine cover:

Remove engine cover -arrows-.

All models:

Release spring clamp -arrow- and push back on air duct hose.

Vehicles with engine code APF:

Detach connector -1-.
Disconnect hoses -2- and -3- at the secondary air pump.
Detach the secondary air pump -4- from the bracket.

Unscrew bolts -1...4- of the secondary air pump bracket.
Lay the wiring aside -arrow- and remove the secondary air pump bracket.

All models:

Important
The fuel system is pressurised. Before opening the system place a cloth around the connection point. Then release pressure by carefully loosening the connection.
Unbolt bracket for engine cover.
Mark fuel feed pipe -2- and fuel return pipe -1- and detach at the fuel rail.

Disconnect vacuum hose -5 - from fuel pressure regulator.
Unplug connectors:

3 -
Hall sender -G40
4 -
Intake manifold change-over valve -N156

Where fitted, unclip the throttle cable at the lower section of the intake manifold.

Remove bolts -1- and -2-.
Lever off the clips -1- and -4-.
Pull the retaining lugs slightly to the side to release -arrows-.

Remove bolts -1...8- and detach the lower section of the intake manifold.
Unclip the wiring duct at the lower section of the lower section of the intake manifold and detach the connectors for the injectors.

Note:

Plug intake ports on cylinder head with clean cloths.

Installing

Installation is carried out in the reverse order; note the following:

Note:

Replace seals and gaskets.

Bond the sealing rings onto the lower section of the intake manifold, between the upper and lower sections of the manifold, with adhesive sealant.
Adhesive sealant

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Tightening torques

Component · Nm
Upper section of intake manifold to lower section · 3
Lower section of intake manifold to cylinder head · 20
Engine cover bracket to lower section of intake manifold · 20