Overview - Charge Air System, 3.0L Engine-Side, Version 1

1. Bolt
   • Tightening Specifications and Sequence. Refer to Fig 3.
2. Upper Air Guide Pipe
   • Removing and installing. Refer to UPPER AIR DUCT PIPE, REMOVING AND INSTALLING .
3. Bolt
   • Tightening Specifications and Sequence. Refer to Fig 3.
   • Thread cutting
   • Position the bolt by hand and tighten it until it finds the old threads. Then tighten the bolt to the specification.
4. Bolt
   • 5 Nm
5. Bolt
   • 8 Nm
   • For model versions
6. Connection
   • Model versions
7. Seal
   • Replace after removing.
   • For model versions
8. Air Duct Pipe
   • There are different versions. Refer to the Parts Information for the allocation.
9. Bolt
   • 9 Nm
10. Seal
    • Replace after removing.
11. Intake Manifold with Crankcase Ventilation Hose
    • 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.
12. Bolt
    • 9 Nm
13. Seal
    • Replace after removing.
14. Turbocharger
    • Overview. Refer to OVERVIEW - TURBOCHARGER, 3.0L ENGINE .
15. 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 .
16. O-Ring
    • Not available separately; replace if leaking -item  ) OVERVIEW - CHARGE AIR SYSTEM, 3.0L ENGINE-SIDE, VERSION 1 - List Item: Intake Air Temperature Sensor -G42- /Manifold Absolute Pressure Sensor -G71- or damaged
17. 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 .
18. Seal
    • Replace after removing.
19. Connection
20. Bolt
    • Step 1: 5 Nm
    • Step 2: 6 Nm
    • Thread cutting
    • Position the bolt by hand and tighten it until it finds the old threads. Then tighten the bolt to the specification.
21. Seal
    • Replace after removing.
22. Intake Manifold
    • Overview. Refer to OVERVIEW - INTAKE MANIFOLD .
23. Seal
    • Replace after removing.
24. 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 Fig 3.

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-.

Check the O-Rings For Damage

-- Check the O-rings for damage and replace if necessary.

1. O-Ring (Black)
2. O-Ring (Blue)
3. Crankcase Ventilation Hose ¹
4. Crankcase Ventilation Hose ¹
5. EVAP System Hose ¹
6. O-Ring (Black)
7. O-Ring (Orange)
8. Crankcase Ventilation Hose ¹
9. Vacuum Hose

¹ the O-ring is not sold separately; if damaged or leaking, then replace the crankcase ventilation hose

Upper Air Duct Pipe - Tightening Specification and Sequence 

(shown on 3.0L engine).

-- Tighten the bolts in the steps shown in the sequence:

Step	Screws	Procedure/Tightening Specifications
1.		Bringing the air duct pipe in the installation position
2a.	-1 to 7-	Air duct pipe on the previous intake manifold: Position and install all the way by hand; this allows the bolts to locate the previous threads.
2b.	-1 to 3-	Air duct pipe on the new intake manifold: Position and install all the way by hand.
3.	-2 through 7-	6 Nm
4.	-1-	9 Nm

Throttle Valve Control Module GX3 - Tightening Specification and Sequence 

-- Tighten the bolts in steps:

Step	Screws	Procedure/Tightening Specifications
1.		Bring the Throttle Valve Control Module -GX3- with the connection in the installation position
2.	-arrows-	Position and install by hand diagonally all the way by doing this the bolts find the previous threads
3.	-arrows-	5 Nm diagonally