Removing and installing right-side intake manifold (bottom section) - vehicles from 10.2004 onwards — AUDI

🧭 Before you start

Remove the top section of the manifold, then the high-pressure pipes, air pipe, intake hose, sender and motor connectors and glow plug plugs. Unbolt and lift off the right-hand bottom section, blocking the intake ports with clean rags. Refit with new seals, reinstall the top section, fit high-pressure pipes hand-tight and stress-free, tighten them with the specified tools, then leak-check at idle, road-test and inspect again.

Fits: Audi A8 D3 (4E, 2002–2010)

• Renewed: seals

Don't miss

• Observe injection system cleanliness rules; block the intake ports in the head with clean rags.
• Renew seals and gaskets on the bottom section.
• Fit high-pressure pipe union nuts hand-tight first and make sure the pipes are not under tension.
• Check all 6 return line connections for leaks; return lines only come with the pressure retention valve.
• Road-test at least 20 km with one full-throttle run, then recheck the high-pressure side for leaks.

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

🔧 Engine codes this applies to

📋 Procedure

1. ⚠ Observe rules for cleanliness when working on the injection system . — Remove intake manifold (top section) .
2. Unscrew union nuts (arrows) and detach high-pressure pipes.
3. Unscrew union nuts (1 ... 4) and detach high-pressure pipes.
4. Release hose clips (arrows) and remove air pipe between turbocharger and air mass meter G70.
5. Remove air intake hose together with crankcase breather hose (arrows).

6. Take electrical connector (arrow) for exhaust gas temperature sender 1G235 out of bracket.
7. Detach electrical connector (3) at intake manifold flap motor V157.
8. Remove bolt (2). [Note: Disregard items (1) and (4).]
9. Unplug electrical connectors at glow plugs on cylinder bank (right-side).
10. Remove bolts (arrows) and detach bottom section of intake manifold (right-side). [Note: Disregard (item 1).Block off intake ports in cylinder head with clean rags.] [Note: Renew seals and gaskets.]
11. Install intake manifold (top section) .
12. Tighten union nuts on high-pressure pipes hand-tight initially.
13. Ensure that high-pressure pipes are not under tension.
14. To tighten union of high-pressure pipe at high-pressure pump, use torque wrenchV.A.G 1331 with socket insert AF 14, flared ring spannerV.A.G 1331/8.
15. To tighten unions of high-pressure pipes at rail elements, use torque wrenchV.A.G 1331 with ratchetV.A.G 1331/1 and socket, 14 mm3150.
16. To tighten unions of high-pressure pipes at rail elements, use torque wrenchV.A.G 1331 with open end spanner insertV.A.G 1331/5.
17. To tighten union of high-pressure pipe at high-pressure pump, use torque wrenchV.A.G 1331 with ratchetV.A.G 1331/1 and socket T40055, 17 mm.
18. Check fuel system for leaks.
19. Run engine at idling speed for several minutes and then switch off.
20. Switch off ignition.
21. Check the complete fuel system including all 6 return line connections for leaks. [Note: The return lines can only be renewed together with the pressure retention valve as one unit.]
22. After completing the repair, road-test the vehicle over a distance of at least 20 km. Accelerate with full throttle at least once. Then inspect the high-pressure section of the fuel system again for leaks. [Note: If there is any air left in the fuel system, the engine may switch to the backup mode ('emergency running' mode) during the road test. Switch off the engine and erase the fault memory. Then continue the road test.]

Other AUDI procedures

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