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Upper Intake Plenum Removal
 
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Pelican Technical Article:

Upper Intake Plenum Removal

Jared Fenton

Time:

1 hour1 hr

Tab:

$0

Talent:

**

Tools:

Hose clamp pliers, T30 Torx driver, screwdriver

Applicable Models:

Audi A6 (1997-04)
Audi A6 Quattro (1997-04)

Parts Required:

Upper Intake Plenum

Hot Tip:

Be careful when removing the turbo feed pipes from the plenum.

Performance Gain:

Access to items underneath plenum

Complementary Modification:

Replace MAF sensor

The C5 Audi A6 2.7T has an upper intake plenum that provides each turbocharger with air to be compressed. Basically a plenum is nothing more than a chamber, located between the throttle body and the runners of an intake manifold, used to distribute the intake charge evenly and to enhance engine breathing. It's rare that a plenum must be replaced for a new one. However, this plenum must be removed in order to gain access to components below when performing several projects. In this article I'll show you how to remove it.

You'll need to remove the engine covers to gain access to the plenum. See our article on Engine Cover Removal for more information.

Shown here is the upper intake plenum on the C5 Audi A6 2.
Figure 1

Shown here is the upper intake plenum on the C5 Audi A6 2.7T. Begin removal by loosening the hose clamps (green arrows) holding the feed pipes to the plenum.

Loosen and slide back the clamp (green arrow) holding the air hose to the rear of the plenum.
Figure 2

Loosen and slide back the clamp (green arrow) holding the air hose to the rear of the plenum. Carefully pull the hose off.

Press the tabs on either side of the plastic connector (green arrows) holding the emissions hose to the plenum.
Figure 3

Press the tabs on either side of the plastic connector (green arrows) holding the emissions hose to the plenum. Pull the plastic connector off.

Loosen and remove the three T30 Torx bolts (green arrows) holding the plenum to the intake manifold.
Figure 4

Loosen and remove the three T30 Torx bolts (green arrows) holding the plenum to the intake manifold.

Carefully lift the plenum up from the rear, then pull it out of the turbo feed pipes at the front.
Figure 5

Carefully lift the plenum up from the rear, then pull it out of the turbo feed pipes at the front. Installing the plenum is the reverse order of removal.

And here's the finished result with the plenum removed.
Figure 6

And here's the finished result with the plenum removed.

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