Intake manifold, removing and installing

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2009 Audi S4, 2008 Audi S4, 2007 Audi S4, 2006 Audi S4, and 2005 Audi S4. However, it is still accessible from the selected car via links, so may be relevant.

Removing

NOTE:

All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

Bring lock carrier into service position → Lock carrier, moving into service position .

Fig 1: Removing Rear Engine Cover

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Remove rear engine cover - arrows -.

Fig 2: Removing Front Engine Cover

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Remove front engine cover - arrows 1 and 2 -.

Fig 3: Disconnecting Brake Booster Vacuum Hose From Grommet On Bulkhead

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Disconnect vacuum line - arrow - to brake booster at bulkhead.

Fig 4: Disconnecting Vacuum Line To Vacuum Reservoir

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If installed, disconnect vacuum line - arrow - to vacuum reservoir.

Fig 5: Disconnecting Vacuum Hose From Intake Manifold

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Disconnect vacuum hose - arrow - from intake manifold.

Fig 6: Disconnecting Electrical Connection At Throttle Valve Control Module J338

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Disconnect electrical connection - 1 - at throttle valve control module J338.
Disconnect vacuum hose - 2 -.
Remove air guide hose - 3 -.
Disconnect crankcase ventilation hose - 4 - at intake pipe.

Fig 7: Disconnecting Vacuum Line

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If installed, disconnect vacuum line at area designated with - arrow -.

Fig 8: Remove Electrical Harness Connectors Toward Front From Brackets On Intake Line

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Remove electrical harness connectors - 1 to 4 - toward front from brackets on intake pipe.

NOTE:

The electrical connections must not be separated.

Fig 9: Disconnecting Vacuum Hose At T-Piece

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Disconnect vacuum hose - arrow - at T-piece.

Fig 10: Identifying Connector Strips At Fuel Injectors, Vacuum Line On Fuel Pressure Regulator & Retaining Bolts For Fuel Rail Line

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Disconnect connector strips - 1 - and - 5 - at fuel injectors.
For vehicles with fuel return line, disconnect vacuum line - 4 - on fuel pressure regulator.
Remove retaining bolts - 2 - and - 3 - for fuel rail line.
Remove fuel distributor together with fuel injectors from intake manifold simultaneously upward and place it on a clean rag in engine compartment.

NOTE:

Carefully protect the removed fuel injectors from contamination.

Fig 11: Removing Left/Rear Engine Lifting Eye

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Remove bolts - arrows - for left rear engine lifting eye.

Fig 12: Removing Intake Manifold Bolts

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Remove intake manifold bolts - arrows - and remove manifold.

NOTE:

Plug intake ports of cylinder head with clean rags.

Installing

Installation is in reverse order of removal, note the following:

NOTE:

Replace gaskets and O-rings.
Secure all hose connections using hose clamps appropriate for the model type .
During installation, all cable ties must be re-installed at the same location.

Fig 13: Replacing Intake Manifold Gaskets, Thereby Removing Locking Bolt

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Replace intake manifold gaskets, thereby removing locking bolt - 1 -.
Be aware of alignment pins - 2 - when setting intake manifold in place.

Fig 14: Tightening Intake Manifold Bolts In Diagonal Sequence And In Steps

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Tighten intake manifold bolts - arrows - in a diagonal sequence and in steps.

Tightening torque: 11 Nm

Install lock carrier with attachments →
- 50 BODY, FRONT
- 50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET
.

Fig 15: Placing Torque Support On Rubber Buffer For Torque Support

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Place torque support on rubber buffer for torque support and tighten bolts - arrows -.
Install front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
Run engine for 5 minutes.
Retighten intake manifold bolts in sequence shown.

Tightening torque: 11 Nm

Check headlight adjustment →
- 01 - MAINTENANCE
- 01 - MAINTENANCE for MAINTENANCE PROCEDURES - CABRIOLET
.

Torque specifications

Component	Nm
Locking bolt to cylinder head	0.6
Intake manifold to cylinder head	11
Engine lifting eyelet to cylinder head	22
Fuel rail pipe to intake manifold	10
Torque support stop to lock carrier	28