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24th February 2009

Audi A6 allroad V6 TDi Engine (AKE)
Front Intake Manifold - Removal and Refitting
Special Tools required: Nothing really, but a comprehensive socket set, complete with flexible shaft and hex/allen key sockets makes this job easier. One of those magnasticks is highly recommended as the possibility of dropping small parts and/or tools is always present on this engine and the limited access to some fixings can be a bit frustrating. Removal: 1. Remove the engine cover. Pulls off on the AKE engine, screws required on other V6 TDi variants.

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2. Optional - Remove the black plastic cover at the hydraulic reservoir to improve visibility and clearance for the task ahead. See below.
3. Remove (pull) the braided hose at the cut-off valve and set it aside. This is obscured from view by the water hoses in the image above.
4. Remove hose where it connects to the front intake manifold. See below.

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5. Using a long allen key or suitable hex driver (5mm) remove the two lower bolt that attach the front intake manifold to each cylinder bank. Care required to not drop these bolts. See below how handy the magnastick is.
6. Again with the long 5mm allen key, loosen the two bolts that attach the EGR valve to the front intake manifold. Once loosened initially, I found it easier to use a socket on a flexible shaft to spin these out. Again care is required so as not to drop these into the V of the engine.

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7. Use a 10mm socket on the two upper bolts of the front intake manifold 8. Check / remove any tie-wraps on the manifold before lifting it away from the engine.
Refitting: This is done in reverse order, but it is wise to get that long hex-headed bolt on the underside of the manifold started in its thread by hand before attaching the other fixings. Gaskets should always be renewed of course. Torque on the manifold and EGR bolts is only 10Nm. Dont forget to refit the braided hose on the cut-off valve and ensure it isnt pinched or rubbing against anything.

-o- End o-

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