Volkswagen Workshop Service and Repair Manuals

Removing and installing complete intake manifold, engine codes BSE, BSF, CCSA, CMXA   Note t  Intake manifold upper part is removed and installed together with intake manifold lower part. t  Always follow safety precautions → Chapter. t  Observe rules for cleanliness → Chapter. Removing –  Remove engine cover. –  Remove intake hose between throttle valve module -J338- and air filter.

–  Pull vacuum hose -arrow- to brake servo off intake manifold.

–  Pull connector -1- off secondary air pump motor. –  Remove pressure hoses -2- and -3- from secondary air pump motor. –  Pull oil dipstick with guide funnel off guide tube and off bracket for secondary air pump.

–  Unscrew bracket with secondary air pump motor from intake manifold -arrows-.

–  Unscrew bolts from fuel rail and separate spreader rivets of cable guide on fuel rail -arrows-.   Note Fuel line can remain connected to fuel rail.

–  Separate electrical connections -arrows- and unclip cables on intake manifold. –  Unclip active charcoal filter system solenoid valve 1 -N80- and coolant hose on intake manifold.

–  Pull off connector -1- and remove throttle valve module -J338--arrows-.

–  Remove one bolt each -arrow- on left and right sides of rear intake manifold mounting.

–  Remove all other bolts -arrows- from intake manifold lower part to cylinder head.

–  Loosen cable guide from fuel rail and evenly pull fuel rail together with injectors off intake manifold lower part. –  Remove intake manifold from cylinder head and place fuel rail together with injectors on a clean cloth in engine compartment.   Note Block off intake ports in cylinder head with clean cloths. Installing Installation is carried out in the reverse order. When installing, note the following: –  Renew seals between intake manifold and cylinder head. –  Renew seals between injector and intake manifold and moisten slightly with clean engine oil. –  Position fuel rail together with injectors against intake manifold and press into place evenly.   Note t  After replacing components of injection system, erase learnt values in engine control unit → vehicle diagnosis tester “Guided fault finding”. t  Secure all hose connections with hose clamps comparable to production standard. Torque settings

Component		Nm
Intake manifold to cylinder head		25
Intake manifold to support		8
Secondary air pump bracket to intake manifold		8
Throttle valve housing to intake manifold		8