Overview - Charge Air System, 2.9L Engine-Side

Fig 1: Exploded View Of Charge Air System, 2.9L Engine-Side

Courtesy of AUDI OF AMERICA, LLC

1. O-Ring
   • Not available separately; replace if leaking -item  ) OVERVIEW - CHARGE AIR SYSTEM, 2.9L ENGINE-SIDE - List Item: Intake Air Temperature Sensor -G42- /Manifold Absolute Pressure Sensor -G71- or damaged
2. Intake Air Temperature Sensor -G42- /Manifold Absolute Pressure Sensor -G71-
   • Removing and Installing. Refer to Intake Air Temperature Sensor -G42- /Manifold Absolute Pressure Sensor -G71-, REMOVING AND INSTALLING .
3. Bolt
   • 5 Nm
4. Upper Air Guide Pipe
   • Removing and installing. Refer to UPPER AIR DUCT PIPE, REMOVING AND INSTALLING .
5. Bolt/Nut
   • Bolt, 9 Nm
   • Nut, 20 Nm
6. Bracket
   • For the lower air duct pipe
   • There are different versions.
7. Bolt
   • 9 Nm
8. Washer
9. Grommet
10. Air Duct Hose
11. Air Duct Hose
12. Lower Air Duct Pipe
    • Removing and installing. Refer to the appropriate Service Information .
13. Bolt
    • 9 Nm
14. O-Ring
    • Only 2.9L engine with electrical compressor
    • Not available separately; replace if leaking -item  ) OVERVIEW - CHARGE AIR SYSTEM, 2.9L ENGINE-SIDE - List Item: Charge Air Pressure Sensor 2 -G447- or damaged
15. Charge Air Pressure Sensor 2 -G447-
    • Only 2.9L engine with electrical compressor
    • Removing and installing. Refer to Charge Air System
16. Bolt
    • 9 Nm
    • Only 2.9L engine with electrical compressor
17. Seal
    • Not available separately; replace if leaking -item  ) OVERVIEW - CHARGE AIR SYSTEM, 2.9L ENGINE-SIDE - List Item: Charge Air Cooler Temperature Sensor 1 -G763- or damaged
18. Charge Air Cooler Temperature Sensor 1 -G763-
    • 22 Nm
    • Removing and Installing. Refer to CHARGE AIR TEMPERATURE SENSOR, REMOVING AND INSTALLING .
19. Seal
    • Replace after removing.
20. Intake Manifold
    • Removing and Installing. Refer to INTAKE MANIFOLD, REMOVING AND INSTALLING, 2.9L ENGINE .
21. Bolt
    • 9 Nm
22. Seal
    • Replace after removing.
23. Turbocharger
    • Cylinder Bank 1 (Right)
    • Overview. Refer to OVERVIEW - TURBOCHARGER, 2.9L ENGINE .
24. Turbocharger
    • Cylinder Bank 2 (Left):
    • Overview. Refer to OVERVIEW - TURBOCHARGER, 2.9L ENGINE .
25. Intake Manifold with Crankcase Ventilation Hose
    • Depending on the version, the replacement part is supplied with a new intake manifold with a changed position for the mounting tab for the wiring harness clip. If this is the case, the clip on the wiring harness must be repositioned appropriately.
    • Removing and Installing. Refer to INTAKE MANIFOLD, REMOVING AND INSTALLING .
    • The crankcase ventilation hose cannot be separated from the intake manifold. Note the information:
      • Crankcase Ventilation Hose on Intake Manifold, Rest of World Vehicles. Refer to the information below.
      • Crankcase Ventilation Hose on Intake Manifold, USA Vehicles. Refer to the information below.
26. Seal
    • Replace after removing.
27. Bolt
    • 9 Nm
28. Seal
    • Replace after removing.
29. Charge Air Cooler Temperature Sensor 2 -G764-
    • 22 Nm
    • Removing and Installing. Refer to CHARGE AIR TEMPERATURE SENSOR, REMOVING AND INSTALLING .
30. Seal
    • Not available separately; replace if leaking -item  ) OVERVIEW - CHARGE AIR SYSTEM, 2.9L ENGINE-SIDE - List Item: Charge Air Cooler Temperature Sensor 2 -G764- or damaged
31. Bolt
    • 9 Nm
32. Lower Air Duct Pipe
    • There are different versions.
    • Removing and installing. Refer to the appropriate Service Information .
33. Spacer Sleeve
34. Throttle Valve Control Module -GX3-
    • Removing and installing. Refer to THROTTLE VALVE CONTROL MODULE -GX3-, REMOVING AND INSTALLING
    • Cleaning. Refer to Throttle Valve Control Module -GX3-, CLEANING .
35. Seal
    • Replace after removing.
36. Connection
37. Bolt
    • Thread cutting
    • Position the bolt by hand and tighten it until it finds the old threads. Then tighten the bolt to the specification.
    • Tightening Specifications and Sequence. Refer to Figure.
38. Intake Manifold
    • Overview. Refer to OVERVIEW - INTAKE MANIFOLD .
39. Seal
    • Replace after removing.
40. Bolt
    • Thread cutting
    • Position the bolt by hand and tighten it until it finds the old threads. Then tighten the bolt to the specification.
    • Tightening Specifications and Sequence. Refer to Figure.
41. Seal
    • Replace after removing.
42. Bolt
    • Tightening Specifications and Sequence. Refer to Figure.

Crankcase Ventilation Hose on Intake Manifold, Rest of World Vehicles 

Courtesy of AUDI OF AMERICA, LLC

The crankcase ventilation hose -2- cannot be removed from the intake manifold -1- without damage.

• Replace the crankcase ventilation hose.
• When installing, make sure the connector coupling clicks into place and does not sit crooked on the intake manifold support -1-.

Crankcase Ventilation Hose on Intake Manifold, USA Vehicles 

Courtesy of AUDI OF AMERICA, LLC

The crankcase ventilation hose -2- must not be disconnected from the intake manifold -1- on USA vehicles.

• The replacement part (refer to Parts Information is supplied with the crankcase ventilation hose -2- connected to the intake manifold -1-.