Removing and installing plastic intake manifold (gradual introduction in model year 2009) — AUDI

🧭 Before you start

Fits: Audi A5 (8T, 2007–2016)

• Opens: fuel
• Special tools named: V.A.G 1331/6
• Renewed: gaskets

Don't miss

• Disregard (item 1).
• Do not open hose connection (3) on USA models. — Unplug electrical connector (2) at activated charcoal filter solenoid valve 1N80 and detach vacuum hose (1).
• Disregard (arrow).Shown from rear with engine removed for illustration purposes.
• Seal intake ducts in cylinder heads with clean cloths.
• Check seals in intake manifold for damage and make sure they are positioned correctly.

🔧 Engine codes this applies to

📐 1 workshop diagram for CAUA

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. ⚠ The fuel system operates under high pressure. The pressure in the high-pressure part of the injection system must be reduced to a residual pressure prior to opening the system .A clean cloth must then be wrapped around the connection and the residual pressure dissipated by carefully loosening the connection. — Disconnect earth wire at battery with ignition switched off.
2. Pull off engine cover panel.
3. Pull cover (1) towards front and lift off.
4. Unplug electrical connector (1) and detach vacuum lines (arrows).
5. Detach vacuum line (4) at air intake hose. [Note: Disregard (item 1).]

6. Disconnect hose (3) for crankcase breather system from air hose by pressing release tabs.
7. Release hose clips (2) and (5) and remove air intake hose.
8. Release hose clips (2) and (5) and move air intake hose clear to one side (crankcase breather hose (3) remains connected).
9. ⚠ Do not open hose connection (3) on USA models. — Unplug electrical connector (2) at activated charcoal filter solenoid valve 1N80 and detach vacuum hose (1).
10. Detach activated charcoal filter solenoid valve 1N80 from bracket and move it clear to the side with hose still attached.
11. Disconnect fuel lines (1 and 4) at high-pressure pumps.
12. Remove bolts (2 and 3).
13. Unplug electrical connector (1) at throttle valve module J338.
14. Unscrew bolts (arrows) and remove throttle valve module J338.
15. Detach vacuum lines (arrows) going to brake servo.
16. Move vacuum lines clear to one side. [Note: Disregard (item 1).]
17. ⚠ Hot steam or hot coolant can escape when coolant expansion tank is opened; cover filler cap with cloth and open carefully. — Open filler cap on coolant expansion tank.
18. Detach crankcase breather hose at the points marked with (item 1) and (item 2) (press release tabs).
19. Clamp off coolant hose (4) using hose clamp (up to 25 mm)3094 and detach coolant hose from intake manifold connection.
20. Slacken bolt (5) a few turns.
21. Unscrew bolts (3) and carefully remove pressure control valve for crankcase breather system from intake manifold connection. [Note: Disregard (arrow).Shown from rear with engine removed for illustration purposes.] [Note: Lay a cloth under the intake manifold connection to catch escaping coolant.]
22. Detach coolant hose (arrow) and move clear to one side.
23. Detach vacuum hose (arrow) going to intake manifold connection.
24. Remove bolts for intake manifold in the sequence (16 to 1).
25. Remove intake manifold from engine compartment. [Note: Seal intake ducts in cylinder heads with clean cloths.] [Note: Renew gaskets, seals and O-rings.Secure all hose connections with the correct type of hose clips (same as original equipment) Parts catalogue.Fit all cable ties in the original positions when installing.]
26. Check seals in intake manifold for damage and make sure they are positioned correctly.
27. Make sure that hoses and wires are not trapped.
28. Tighten bolts for intake manifold in the sequence (1 to 16). [Note: The connections of the high-pressure pipes must not be damaged.Do not attempt to bend high-pressure pipes to a different shape.]
29. Tighten union nuts on high-pressure pipes hand-tight initially.
30. Ensure that high-pressure pipes are not under tension.
31. To tighten union nuts (14 mm) for high-pressure pipes, use torque wrenchV.A.G 1331 with socket insert AF 14, flared ring spannerV.A.G 1331/8.
32. To tighten union nuts (17 mm) for high-pressure pipes, use torque wrenchV.A.G 1331 with tool insert (17 mm)V.A.G 1331/6.
33. Do not install mounting brackets until high-pressure pipes have been finally secured.
34. Observe notes on procedure after disconnecting the battery Electrical system27Battery; Disconnecting and connecting battery.
35. If necessary, fill up with coolant .

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