Removing and installing upper section of intake manifold — AUDI

APG
Note:

The following description of removal and installation relates to vehicles with electronic throttle, secondary air system and exhaust gas recirculation. Some procedures do not apply for vehicles with older components.

Caution!
On vehicles equipped with telematics the telematics control unit must be switched to service mode before the battery terminals are disconnected.=>Radio, telephone and navigation system; Repair group 91
Obtain code on vehicles with coded radio/integrated radio and navigation system.
With ignition switched off disconnect battery earth strap.
Drain cooling system=> Page
19-4
.

Remove engine cover panel -arrows-.

Unplug electrical connector -3-.
Disconnect hoses -1- and -4-.
Remove bolt -6-.
Remove air duct by releasing spring clamps -2- and -5-.

Disconnect hose -arrow- on secondary air inlet valve -N112.

Disconnect hoses -1 ... 4-.

Unplug electrical connector -4- from throttle valve control part -J338.
Remove earth wire -3-.
Remove bolts -1- and -2- and disconnect exhaust gas recirculation pipe from top of throttle valve housing.

Unplug connector -1- from intake manifold changeover valve - N156.
Disconnect vacuum hoses -2- and -3-.
Disconnect spark plug connectors.

Unscrew upper section of intake manifold from rear support bracket -arrows-.

Note:

Shown in illustration with engine removed.

Unscrew bolts -arrows- and remove upper section of intake manifold.

Note:

Plug inlet passages of lower section of intake manifold with clean cloths.

Installing

Install in reverse sequence; note the following points:

Vehicles with throttle cable:

Adjust throttle cable:

=> Fuel supply system - Petrol engines; Repair group 20; Servicing accelerator mechanism - Vehicles with mechanical throttle cable.
Fuel supply system - Petrol engines
Servicing accelerator mechanism - Vehicles with mechanical throttle cable.

All models

Notes:

Renew gaskets.
When the battery is reconnected, re-activate electrical equipment (radio, combined radio/navigation system, clock, electric windows) as described in the Owner's Manual.
De-activate service mode in telematics control unit.

=> Radio, telephone and navigation system; Repair group 91
Radio, telephone and navigation system

Further procedures after reconnecting the voltage supply:

=> Motronic injection and ignition system; Repair group 24
Motronic injection and ignition system

Fill up with coolant=> Page
19-7
.

Tightening torques

Component · Nm
Upper section of intake manifold to lower section of intake manifold · / 10
Upper section of intake manifold to support bracket · / 10
Earth connection to throttle valve control part · / 10