Intake manifold, removing and installing: Removing

WARNING: This page is about a different car, the 2006 Audi A4, 2005 Audi A4, 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

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

Drain coolant. Refer to Coolant, draining and refilling .

WARNING:

Observe safety precautions when disconnecting the battery.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

See Caution before beginning repairs on the electrical system. Refer to Cylinder head, removing and installing

Switch ignition off and disconnect battery Ground (GND) strap.

Fig 1: Removing Rear Engine Cover

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove rear engine cover (arrows).

Fig 2: Removing Front Engine Cover

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove front engine cover (arrows).

Fig 3: Removing Cover In Engine Compartment (Right Side)

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove cover -1- in engine compartment (right side).

Fig 4: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts (arrows).
Detach Evaporative Emission (EVAP) canister purge regulator valve -N80- -1- at air guide.
Remove air guide -2-.

Fig 5: Removing Air Filter Housing

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove air filter housing (arrows).
Disconnect electrical harness connector -1- at Mass Air Flow (MAF) sensor.
Remove air guide hose -2- together with Mass Air Flow (MAF) sensor.

Fig 6: Identifying Vacuum Hoses & Electrical Harness Connector

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect vacuum hoses -2- and -3- at Intake manifold change-over valve -N156-.
Disconnect vacuum hose -6- from check valve.
Disconnect electrical harness connector -5-.
Set aside hose of crankshaft housing ventilation (arrow).

Remove bolts -1-, -4- and -7- for holding plate for solenoid valves.
Remove holding plate for solenoid valves.

Fig 7: Disconnecting Electrical Harness Connector & Pulling Off Vacuum Hose At T-Connector

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector -1-.
Pull off vacuum hose -2- at T-connector.
Remove all harness connectors to injectors.

Fig 8: Disconnecting Vacuum Line At Fuel Pressure Regulator And Removing Mounting Bolts Of Fuel Pressure Regulator

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect vacuum line at fuel pressure regulator and remove mounting bolts of fuel pressure regulator (arrows).
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 removed fuel injectors from contamination.

Fig 9: Identifying Throttle Valve Control Module -J338- Electrical Harness Connector & Vacuum Hoses

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector -1- at Throttle valve control module -J338-.
Disconnect vacuum hoses -2- and -3-.

Fig 10: Identifying Air Duct Hose, Bolt, Air Duct & Vacuum Hose

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect hose -1- from air duct.
Remove bolt -4- and disconnect air duct -2- at throttle valve control module.
If installed, disconnect vacuum hose -3- from air guide at bottom.

Fig 11: Disconnecting Vacuum Line To Leak Detection Pump At Throttle Valve Control Module

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect vacuum line (arrow) to leak detection pump at throttle valve control module.

Fig 12: Identifying Bolts, Hose From Line Of Secondary Air Injection

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts -1- and -3-.
Pull out guide tube for oil dipstick 2 from the oil pan (upper part) toward top and swing it forward for removal.

NOTE: Hose -4- remains connected.

Fig 13: Removing Bolts At Right Side Of Engine At Line For Secondary Air Injection

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts at right side of engine (arrows) at line for secondary air injection.

Fig 14: Removing Bolts At Lines Of Secondary Air Injection & Resonator

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts -1- and -2- at lines of secondary air injection.
Remove bolts -3- and -5- and remove resonator -4-.

Fig 15: Identifying Vacuum Hose At EVAP Valve & Coolant Hoses

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect vacuum hose -1- at EVAP valve.
Remove coolant hoses -2- and -3-.

Fig 16: Unbolt/Bolting Intake Pipe

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt intake pipe (arrows) and remove.

NOTE: Plug intake channels in the cylinder heads with clean rags.