Intake Manifold: Removing

WARNING: This page is about a different car, the 2012 Audi S5, 2011 Audi S5, 2010 Audi S5, 2009 Audi S5, and 2008 Audi S5. However, it is still accessible from the selected car via links, so may be relevant.

WARNING:

Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure. Refer to BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .
Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.

NOTE:

During Installation, All Cable Ties Must Be Re-Installed At The Same Location.

CAUTION:

Risk Of Destroying Electrical Components When Battery Is Disconnected.

Observe measures when disconnecting battery.
Only disconnect battery with ignition switched off.

-- Disconnect battery. Refer to BATTERY .

-- Remove the engine cover -arrows-.

Fig 1: Identifying Engine Cover

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-- Disconnect fuel lines -1, 3, 4 and 6-.

Fig 2: Identifying Fuel Lines & Bolts

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-- Remove bolts -2- and -5- and remove fuel rail with high pressure lines.

-- Free up fuel line and vacuum line to EVAP canister on air guide hose.

-- Disconnect the electrical connector -2- on Solenoid Valve 1 for the EVAP Canister -N80- and disconnect the vacuum hose -1-.

Fig 3: Disconnecting Electrical Connector -2- On EVAP Canister Purge Regulator Valve 1 -N80- & Disconnect Vacuum Hose -1-

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-- Remove the Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- from the bracket and lay it aside with the hose connected.

-- Disconnect electrical connector -1- on Mass Air Flow (MAF) Sensor -G70-.

Fig 4: Disconnecting Connector On Mass Airflow (MAF) Sensor

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-- Disconnect the vacuum line -3- to the air guide pipe.

CAUTION:

Risk Of Violating Emissions Legislation.

Do not open hose connection -2- !

-- Loosen the clamps -4-, open the clips -arrows- and move the air guide hose to the side with the crankcase ventilation hose still connected -2-.

Fig 5: Disconnecting Connector On Mass Airflow (MAF) Sensor

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-- Disconnect vacuum hose -2-.

Fig 6: Disconnecting Vacuum Hose -2-

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NOTE:

Ignore -1-.

-- Disconnect electrical connector -1- on Throttle Valve Control Module -J338-.

Fig 7: Disconnecting Electrical Connection At Throttle Valve Control Module J338 & Removing Bolts And Throttle Valve Control Module J338

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-- Remove bolts -arrows- and remove Throttle Valve Control Module -J338-.

-- Loosen bolt -3- a few turns.

Fig 8: Loosening Bolt -3-

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-- Remove the bolts -2- and remove the crankcase ventilation pressure control valve from the throttle valve connection.

NOTE:

Ignore -1- and -arrow-.

To provide a better illustration, component location is shown from behind with engine removed.

WARNING:

Cover The Coolant Reservoir Cap With A Cloth And Open Carefully Because Steam Or Hot Coolant May Escape When Opening.

-- Open the cap on the coolant reservoir.

-- Disconnect and remove the coolant hose -1- with Hose Clamps Up to 25 mm diameter:3094 .

Fig 9: Identifying Coolant Hoses, Vacuum Hose & Bolts

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-- Remove the coolant hose -2-.

-- Disconnect the vacuum hose -3- and move it to the side.

-- Remove the bolt -4- on the high pressure line clamp.

-- Remove the bolts -1- and remove the left rear engine lifting eye.

-- Remove the bolt -2- on the wiring harness bracket.

Fig 10: Removing Bolt -2- On Wiring Harness Bracket

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-- Remove the bolts -3- and move the left front engine lifting eye and the connectors to the side.

-- Push the wiring harness to the left side.

-- Remove the bolt -3- and remove the right rear engine lifting eye.

Fig 11: Identifying Lifting Eyes & Bolts

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-- Remove the bolt -2- on the wiring harness bracket.

-- Remove the intake manifold bolts in sequence -10 through 1-.

Fig 12: Identifying Intake Manifold Bolts Removal/Tightening Sequence

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-- Cover the high pressure lines to avoid scratching the intake manifold.

-- First lift the intake manifold toward the front and then up -arrow 1-.

Fig 13: Identifying Intake Manifold

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-- Disconnect the connectors.

Fig 14: Identifying Connectors

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Intake Flap Motor -V157- (brown connector)
Intake Manifold Runner Position Sensor -G336-
Variable Intake Manifold Runner Motor -V183- (black connector)
Intake Manifold Runner Position Sensor 2 -G512-

NOTE:

To Provide A Better Illustration, Component Location Is Shown From The Front With The Engine Removed.

-- Move the intake manifold toward the right side of the vehicle under the high pressure fuel lines -arrow 2-.

-- Remove the intake manifold from the engine compartment.

CAUTION:

The Engine Could Be Destroyed.

Cover the intake chambers in the cylinder heads with a clean cloth to prevent small parts from falling in the combustion chambers.