How to Replace the Intake Manifold in a VW Passat

Take off the engine cover and set it aside. Drain about half the engine coolant and take out the coolant expansion tank. Disconnect the negative battery cable.

Disconnect the throttle cable and the actuator rod on models with cruise control. Label all the electrical connectors and detach them. Take the upper intercooler hose out of the throttle body.

Release the pressure in the fuel system, then remove the fuel rail and injectors. Locate the upper coolant pipe and pull it form the engine along with the coolant hoses. Remove the oil dipstick.

Label and disconnect any remaining vacuum lines and wiring that would otherwise get in the way of the manifold removal. Loosen and remove lower support brace.

Remove bolts holding the manifold in place. Lift the manifold and the throttle body assembly from the engine. Drape clean shop rags over the head ports to keep dirt and debris from falling into the engine compartment.

Scrape away all traces of gasket material from the manifold and cylinder head. Use acetone or solvent to clean the mating surfaces.

Install the new gasket. Set the manifold on the head and replace the nuts and bolts.

Make three or four passes to tighten the bolts. Work from the center out to the ends to avoid warping the manifold.

Replace and reconnect all the hoses, lines and wires in the reverse order of removal. Add coolant to bring it to the recommended level. Start the engine and check for leaks of vacuum or coolant.

Road test the vehicle to ensure proper operation. Make sure the cruise control is properly working.