Removing and installing upper section of intake manifold - vehicles with engine codes AEH, AKL — AUDI

AKL APF
Special tools, workshop equipment, and other items required

Hose clamps 3094
Adhesive sealant

=> Parts List

Removing

Remove the front engine cover -arrows-.

Disconnect the air duct hose -1- from the air mass meter.
Unplug connector -2- at air mass meter.
Unscrew bolts -3- and -4-.
Remove air cleaner housing.

Disconnect hoses -1- and -3-.
Remove the air duct, release spring clamp -2- for this purpose.

Detach the throttle cable -arrows-.
Disconnect hose -1- to ACF.
Unplug connectors:

2 -
Intake air temperature sender -G42
3 -
Throttle valve control part -J338

Lay wiring aside.

Clamp off coolant hoses with hose clamps 3094.
Disconnect the coolant hoses at the throttle valve connection.

Detach the vacuum hose -arrow- to the brake servo at the intake manifold.
Turn the breather housing clockwise and detach from the cylinder head.
Close off the openings in the cylinder head cover with a clean cloth.

Unplug connector -1- at intake manifold changeover valve -N156.
Disconnect vacuum hose -2-.

Detach earth strap at bracket for upper section of intake manifold.
Remove the two bolts arrow on the rear intake manifold mounting (one on the left, one on the right) -arrow-.

Remove bolts -1- and -2-.
Where fitted, lever off the clips -1- and -4-.
Pull the retaining lugs slightly to the side to release -arrows-.
Press off the upper section of the intake manifold from the lower section rearwards.

Note:

Plug the intake ports of the intake manifold (lower section) 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

=> Parts List

Push the upper section onto the bottom section of the intake manifold and bolt into place.
Allow the retaining lugs on the left and right to engage and secure each with a clip.
Coat the collar of the bolts for the rear intake manifold mounting with silicone-free lubricant and tighten.
Lubricant

=> Parts List

Adjust throttle cable:

=> Fuel Supply System - Petrol Engines; Repair group 20; Servicing throttle mechanism - Vehicles with mechanical throttle mechanism
Fuel Supply System - Petrol Engines
Servicing throttle mechanism - Vehicles with mechanical throttle mechanism

Top up coolant => Page
19-52
.

Tightening torques

Component · Nm
Upper section of intake manifold to lower section · 3
Upper section of intake manifold to support · 10
Earth wire to support for upper section of intake manifold · 10