Volkswagen Workshop Service and Repair Manuals

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 off hoses -2- and -3- off secondary air pump. –  Unbolt secondary air pump -4- from bracket. –  Pull oil dipstick with guide funnel off guide tube and off bracket for secondary air pump.

–  Remove bolts -1- and -2- as well as nut -3- for secondary air pump bracket. –  Release tension from poly V-belt and lock tensioning element using locking pin -T10060-.

–  Remove deflector plate -arrows-.

–  Unscrew bolts from fuel rail and loosen spreader rivets of cable guide on fuel rail.   Note Fuel line remains connected to fuel rail. –  Separate vacuum line to active charcoal filter system solenoid valve 1 -N80- and unclip it from intake manifold.

–  Separate electrical connections on intake manifold -arrows- and unclip cables.

–  Clamp off coolant hose to heat exchanger for heating system using hose clip -3094-. –  Remove coolant hoses -1- and -2- from throttle valve housing. –  Free coolant hose to expansion tank on intake manifold.

–  Separate electrical connection -3- from throttle valve module -J338-. –  Remove bolts -1- and -2-.

–  Remove throttle valve module -J338--arrows-.

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

–  Disconnect cable clamp -2-. –  Remove union nut -1-. –  Remove nuts -3- and remove connecting pipe for exhaust gas recirculation.

–  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.