Removing and installing intake manifold, engine codes BKC, BXE — VW

🧭 Before you start

Fits: VW Golf V / Jetta (1K, 2003–2009)

• Renewed: gaskets

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• Hoses (2) remain connected.

🔧 Engine codes this applies to

📐 41 workshop diagrams for BKC

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Remove engine cover. [Note: Hoses (2) remain connected.]
2. Detach lines (2) from air pipe.
3. Remove air pipe. Raise retaining clips (1) slightly to do so.
4. Disconnect connector (2) at air mass meter G70.
5. Detach vent hose (1) and air hose (3).

6. Separate connector (arrow) at intake manifold flap motor V157.
7. Unscrew bolts (1 ... 3) and remove intake manifold flap motor V157.
8. Remove intake connecting pipe with potentiometer for exhaust gas recirculation G212 and exhaust gas recirculation valve N18.
9. Clamp off and detach coolant hoses (1) and (2) at cooler for exhaust gas recirculation with hose clips up to Ø 25 mm3094.
10. Clamp off and detach coolant hoses (1) and (2) with hose clips up to Ø 25 mm3094.
11. Detach vacuum hoses (arrow 2).
12. Detach vacuum hose (arrow 3) from non-return valve for brake servo.
13. Pull vacuum hose (arrow) off tandem pump leading to brake servo.
14. Unbolt engine lifting eye at rear of cylinder head (arrow).
15. Unscrew bottom connecting pipe from changeover valve for exhaust gas recirculation (arrows).
16. Unscrew bolts (arrows).
17. Unscrew cooler for exhaust gas recirculation with changeover valve from intake manifold (arrows) and remove.
18. Unscrew intake manifold (arrows). [Note: Renew gaskets and seals.Observe installation location for intake manifold seal.It is very important to observe notes on installing air pipes with connector .Hose connections must be secured with clamps Electronic parts catalogue.]
19. Fill with coolant .

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