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How to Replace the Exhaust Manifold in a VW Jetta

The Volkswagen Jetta boasts a following that only a few other small cars can claim. As the best selling model of VW in the U.S., Jetta was successfully redesigned in the mid-1990s and became the compact of choice for first-time car buyers in their 20s. As the buyers headed towards 30, Jetta was transformed to a mid-size family sedan. The following steps guide you through the removal and installation of the exhaust manifold on the fifth generation (2005 to 2008) gas-powered Jetta.



Difficulty: ChallengingInstructions
    Remove the Exhaust Manifold
  1. Step 1

    Put the vehicle on a lift or on jackstands. Make sure the support is secure.

  2. Step 2

    Disconnect the negative battery cable. Remove any heat shields that are in the way, and then disconnect the oxygen sensor wiring. Remove the exhaust support brackets as needed.

  3. Step 3

    Take the front exhaust pipe from the manifold or the turbocharger. Loosen the exhaust manifold nuts and bolts and remove them. Lift the manifold from the engine.

  4. Step 4

    Discard the old gasket. Use solvent to clean any gasket material from the exhaust manifold surface.

    5. Install the Exhaust Manifold
  5. Step 1

    Coat the stud bolts on the cylinder head with hot bolt paste. Set a new gasket in place and then position the exhaust manifold on the engine.

  6. Step 2

    Tighten the bolts in sequence, working outward from the center in a criss-cross pattern. Torque the bolts to 18 foot pounds.

  7. Step 3

    Bolt the exhaust pipe to the manifold with a new gasket. Use new self-locking nuts and torque them to 30 foot pounds.

  8. Step 4

    Reverse the procedure to reconnect hoses and connections that were removed earlier. Reconnect the negative battery cable.

  9. Step 5

    Start the engine. Check for any exhaust leaks.

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Pre：How to Replace the Exhaust Manifold in a Toyota Tundra   Next：How to Replace the Intake Manifold in a VW Passat

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