VW Passat & Audi A4 1990-2000

Exhaust Manifold(s)

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REMOVAL & INSTALLATION
1990-97 Passat Models
  1. Disconnect the Oxygen (O 2 ) sensor wiring and remove any heat shields that may be in the way.
  2.  
  3. Remove exhaust support brackets as necessary.
  4.  
  5. Detach the front exhaust pipe from the manifold or turbocharger.
  6.  
  7. If equipped, remove the turbocharger.
  8.  
  9. Remove the self-locking nuts or bolts and remove the manifold.
  10.  



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Fig. Exploded view of the exhaust manifold mounting and related components-2.0L (ABA) engine



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Fig. Remove the emissions testing tube



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Fig. Heat shield bolt location



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Fig. Remove the exhaust manifold heat riser by sliding it towards the firewall and then pulling it up and out



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Fig. Once the exhaust manifold bolts have been removed, pull the manifold toward the firewall and then out



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Fig. It is advised that you replace the exhaust manifold gasket every time the manifold is removed. This will ensure a tight seal to the head.



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Fig. View of exhaust manifold to down pipe gasket



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Fig. Exhaust manifold bolts are subject to extreme amounts of heat. This may lead them to break off upon removal. You may have to drill out the broken stud



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Fig. Always use two hands when using and easy out or screw extractor



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Fig. Slowly turn the screw extractor into the screw. The use of penetrating oil is recommended



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Fig. Exhaust pipe-to-manifold torque sequence-2.0L (ABA) engine



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Fig. Exploded view of the exhaust manifold mounting and related components-2.8L VR6 engine

To install:

  1. Installation is the reverse of removal. Use new gaskets and self-locking nuts and tighten to 18 ft. lbs. (25 Nm).
  2.  
  3. If the exhaust pipe is bolted to the manifold, install a new gasket and use new self-locking nuts. Tighten the nuts to 30 ft. lbs. (40 Nm).
  4.  
  5. Check and clear any Diagnostic Trouble Codes (DTCs).
  6.  

A4 & 1998-00 Passat Models
1.8L Engine
  1. Remove the turbocharger.
  2.  
  3. Seal any openings in the turbo with clean shop rags to prevent debris from entering.
  4.  
  5. Remove the exhaust manifold mounting nuts, and then remove the manifold.
  6.  
  7. Seal openings in the cylinder head and exhaust pipe with clean shop rags to prevent debris from entering.
  8.  

To install:

  1. Remove the shop rags from the cylinder head, install the exhaust manifold and tighten the mounting nuts to 18 ft. lbs. (25 Nm).
  2.  
  3. Remove the shop rags from the turbo and exhaust pipe, and then install the turbo.
  4.  

2.8L V6 Engine

Right Exhaust Manifold Removal

  1. To remove the right side exhaust manifold:
  2.  
    1. Disconnect the negative battery cable.
    2.  
    3. Detach and remove the heated Oxygen (O 2 S) sensor.
    4.  
    5. Unbolt the exhaust system from the manifold.
    6.  
    7. Remove the heat shield.
    8.  
    9. Remove the manifold nuts, then the manifold.
    10.  
    11. Clean all gasket mating surfaces.
    12.  


To install:

  1. Install the manifold using a new gasket, and tighten the mounting nuts to 18 ft. lbs. (24 Nm).
  2.  
  3. Install the heat shield.
  4.  
  5. Connect the exhaust system to the manifold using a new gasket.
  6.  
  7. Install, then attach the heated O 2 S sensor.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Enter the radio security code.
  12.  
  13. Start the vehicle and check for leaks.
  14.  

Left Exhaust Manifold Removal

  1. To remove the left side exhaust manifold:
  2.  
    1. Disconnect the negative battery cable.
    2.  
    3. Drain the engine coolant into a sealable container.
    4.  
    5. Detach and remove the Oxygen (O 2 S) sensor.
    6.  
    7. Unbolt the exhaust system from the manifold.
    8.  
    9. Unbolt, and if necessary, remove the coolant tube from the cylinder head.
    10.  
    11. Remove the heat shield.
    12.  
    13. Disconnect the Exhaust Gas Recirculation (EGR) tube from the rear of the manifold.
    14.  
    15. Remove the manifold nuts, then the manifold.
    16.  
    17. Clean all gasket mating surfaces.
    18.  


To install:

  1. Install the manifold using a new gasket, and tighten the mounting nuts to 18 ft. lbs. (24 Nm).
  2.  
  3. Connect the exhaust system to the manifold using a new gasket.
  4.  
  5. Install, then attach the heated O 2 S sensor.
  6.  
  7. Connect the EGR tube to the rear of the manifold.
  8.  
  9. Install the heat shield.
  10.  
  11. Attach the coolant tube to the cylinder head.
  12.  
  13. Fill the engine with coolant.
  14.  
  15. Connect the negative battery cable.
  16.  



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Fig. Exploded view of the exhaust manifold mounting and related components-2.8L 5V V6 engine

 
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