Intake manifold upper-part, removing and installing

WARNING: This page is about a different car, the 2009 Audi A4, 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Removing

NOTE:

All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

Fig 1: Removing Rear Engine Cover

GW00017835

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull rear engine cover off - arrows -.

Fig 2: Identifying Front Engine Cover

GW00017827

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull front engine cover off - arrows -.

Fig 3: Disconnecting Check Valve From Connection At Air Duct Hose

GW00017850

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect check valve - 1 - from connection at air duct hose.
Remove air duct hose, thereby loosening hose clamp - 2 - and opening clips - arrows -.

Fig 4: Disconnecting Electrical Harness Connectors

GW00018747

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connectors.

Intake Manifold Flap Change-over Valve N239
Intake Manifold Tuning (IMT) Valve Position Sensor G513

Remove vacuum lines - arrow A - and - arrow B -.
Disconnect vacuum hose - arrow C - at leak detection pump.

Fig 5: Identifying Electrical Harness Connectors

GW00018740

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connectors.

Camshaft Adjustment Valve 1 N205
Throttle valve control module J338
Evaporative Emission (EVAP) Canister Purge Solenoid Valve N80
Intake Air Temperature (IAT) Sensor G42/Manifold Absolute Pressure (MAP) Sensor G71
Intake Manifold Runner Control (IMRC) Valve N316

Free up wiring harness.

Fig 6: Disconnecting Vacuum Hose

GW00018748

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect vacuum hoses - arrows -.
Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - 1 - from Throttle Valve Control Module J338.

Fig 7: Disconnecting Crankcase Breather Hose At Pressure Regulator Valve

GW00018749

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect crankcase breather hose at pressure regulator valve - arrow -.

NOTE:

To improve clarity, the removed engine is shown from the rear.

Fig 8: Removing Bolts And Intake Manifold Upper-Part

GW00018750

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows - and remove intake manifold upper-part.

NOTE:

Plug intake ports of the cylinder head with clean rags.

Installing

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

NOTE:

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

Torque specifications

Component	Nm
Intake manifold upper-part to intake manifold lower-part	6 ¹⁾
Hose clamps 9 mm wide	3
¹⁾ Tighten diagonally in stages.