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Remove the intake manifold from the AEL engine

 
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Burki
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Post09-12-2004, 15:06    Subject: Remove the intake manifold from the AEL engine Quote

Hello fellow mechanics,

While replacing the air filter on my beloved Audi (C4, AEL engine), I noticed a crack in the thick hose leading to the intake manifold. It's clear that I need to replace this hose, and it would probably be best to verschandeln the entire intake manifold. Now, I have a few questions (I enjoy working on cars, but I'm not a professional):

- Are there any tips or instructions for removing the intake manifold specifically for the AEL engine? For example, information on how many bolts it uses to attach to the engine block in different locations, torque specifications, and any special tools required? Unfortunately, searching the forum only yields general information.
What is the function/name of the hose (the thick one that slopes downwards at the front of the intake manifold)? I want to know so I don't look like an idiot when I go to the VW/Audi dealer.
'There's quite a bit of Russian fluid leaking from the crack. Is this normal, or does it indicate other problems (e.g., a faulty EGR valve)?'
If I manage to do it myself, I'll also take some pictures and write a report.
Oh yeah, he also has a loss of power, but I just replaced the glow plugs and the EGR valve is freshly sealed and adjusted (thanks to VAG-COM and the guides here on the forum). It's probably due to the crack...

Thank you for your replies & best regards.
Burki.


Translated on 21-07-2026, 10:58.
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christians
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Post09-12-2004, 23:58    Subject: Remove the intake manifold from the AEL engine Quote

Hi,
I would simply call it a pressure hose. It cost me 140 German Marks back then.
The expansion is not critical; I haven't counted the screws. They were tightened based on feel. There's only a little bit of limited space for tools. I hope you have more than just a simple Allen wrench in your toolbox.
Gruß Christian
A6 BPP, Ex-A6 AKN (Gurke), Ex-Audi100 92 AAT (5Zyl.)


Translated on 21-07-2026, 11:00.
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Burki
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Post10-12-2004, 12:04    Subject: The tools are here... Quote

Okay, I'm equipped with the tools. By the way, I'm currently at the dealership; the hose costs 90 euros and doesn't have a specific name (it's the connection hose between the intercooler and the intake manifold). To install it, you need to remove the right headlight because there's not enough space otherwise. But as I saw today, quite a bit of soot is coming out of the crack, so something else might be broken... any tips on what that could be?


Translated on 21-07-2026, 11:01.
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christians
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Post10-12-2004, 13:57    Subject: Remove the intake manifold from the AEL engine Quote

The soot is coming from the exhaust gas recirculation system, which runs through a channel in the intake manifold all the way to the front. I can't say whether this is still normal. But if you're already taking off the intake manifold, you might as well test the EGR valve to see if it's working properly.
Gruß Christian
A6 BPP, Ex-A6 AKN (Gurke), Ex-Audi100 92 AAT (5Zyl.)


Translated on 21-07-2026, 11:02.
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Burki
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Post10-12-2004, 21:17    Subject: ... and then she's gone... Quote

Here's a quick update: ... The intake manifold has been removed. It's not excessively dirty inside, although I estimate the engine has about 200,000 km on it, with maybe about a millimeter of buildup. I wouldn't have even bothered to take out the dust cloth at home, but here I'll verschandeln it properly. Unfortunately, the dealership didn't have a new gasket for the intake manifold; they said the old one would be fine. Torque specifications? There aren't any, just tighten it until it's secure. If they repair everything like this... Oh yes, the EGR valve moves freely, but the solenoid is rattling. That could also be due to the crack in the hose. I took some pictures; probably boring for professionals, but maybe interesting for hobby mechanics. Tomorrow, I'll start putting it back together.


Translated on 21-07-2026, 11:03.
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Burki
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Post17-12-2004, 14:16    Subject: ... done! Quote

Okay, just wanted to let you know that everything is done. And it's running like new again! If anyone wants more details, I have photos and wrote a report. It's not particularly professional, but if someone wants it, feel free to take it.


Translated on 21-07-2026, 11:05.
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