Table of contents: Removal ↓ Installation ↓
Removal
Remove the engine hood. If available, disconnect the bracket, remove the engine cover "arrows". Remove the noise insulation located underneath.
Using a screwdriver, remove caps "3" and "4" from the two-piece windshield wiper arm. Loosen the nuts on the two-piece windshield wiper arm a few turns. Release levers "1" and "2" by gently rocking them on the windshield wiper axles. Unscrew the nuts completely and remove the two-piece windshield wiper arm.
Disconnect the windshield washer fluid tube "3". Disconnect the plug connectors "4" and "5" of the heated washer nozzles. Release the hose clamp "6" using hose clamp pliers "V.A.G 1921" and remove the drain hose from the fairing grille. Remove the rubber seal "1" of the fairing grille. Remove the fairing grille "2".
Unscrew the bolts and nuts "arrows". Pull the air intake duct forward and remove it, turning it to the right side of the car.
Disconnect the air duct hose "2" from the mechanical EGR valve and set it aside. Disconnect the vacuum hose "3" from the mechanical EGR valve. Disconnect the vacuum hose "4" from the vacuum receiver of the intake manifold flap. Disconnect the hose "1" of the crankcase ventilation system "arrow" and set it aside.
Remove the sound insulation. Remove the heat shield of the exhaust manifold "arrows".
Remove the connecting pipe of the exhaust gas recirculation system "arrows".
Unscrew the "arrow" bolts and remove the intake manifold.
Installation
Installation is in the reverse order, replacing the gaskets, seals and self-locking nuts. The supercharging system must be airtight. The hose fittings and hoses of the air supercharging system must be cleaned of oils and grease before installation. Use clamps of the appropriate series to secure all connections and hoses. Install the wiper arm.
Tightening torques:
- Intake manifold to cylinder head: 22 Nm
- Heat shield to exhaust manifold: 22 Nm 1)
- Connecting tube of the exhaust gas recirculation system:
- to mechanical EGR valve: 22 Nm
- to exhaust manifold: 22 Nm
- Engine cover to bracket: 5.5 Nm
1) Replace the nuts.
The text is based on materials from the website: AUDImanual