Removing and installing upper part of intake manifold — VW

🧭 Before you start

Fits: VW Touran I (1T, 2003–2015), VW Passat B6 (3C, 2005–2010), VW Passat B7 saloon (362, 2010–2014), VW Passat B7 Variant (365, 2010–2014)

Don't miss

• Warning: residual gas may escape when opening! The quantity of the escaping gas is small, and the pressure is low.
• Ensure correct position of the clamp on noise insulation.The clamp must be positioned so that it is still easily accessible after installation of the intake manifolds.
• The intake connecting pipe can now be removed upwards.
• Natural gas system may not be operated until tested accordingly.

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. ⚠ Make sure that the tank shut-off valve on each of the natural gas tanks is closed. — Empty gas system Fuel supply system – natural gas engines20Fuel tank; Releasing pressure in high-pressure line.
2. Lift engine cover panel at points (1), and remove it in direction of (arrow).
3. Open connection (1) at gas rail whilst counterholding at rail (2) with open-end spanner, »AF 16 mm«. [Note: Warning: residual gas may escape when opening! The quantity of the escaping gas is small, and the pressure is low.]
4. Disconnect hoses from intake manifold.
5. Loosen bolts (arrows), and remove intake manifold.

6. Open hose clamps (1) and (2), and pull off intake hose.
7. Pull off connectors (a) and (b).
8. Loosen hose clamps (arrows), and pull off hoses.
9. Loosen bolts (1) and (2).
10. Pull off hoses »item 5« and »item 10«.
11. Also pull off hose of crankcase breather valve »item 11«.
12. Remove hose set, and place it to right side. [Note: Ensure correct position of the clamp on noise insulation.The clamp must be positioned so that it is still easily accessible after installation of the intake manifolds.]
13. Open clamp (a), and slide it in direction of (arrow).
14. Unscrew clamp »item 9«, and push charge air hose »item 10« off throttle valve module J338(7).
15. Unscrew 5 securing bolts (arrows) of intake connecting pipe.
16. Pull pressure sender connector off gas rail. Disconnect all remaining hoses still connected to intake connecting pipe. [Note: The intake connecting pipe can now be removed upwards.]
17. Disconnect connector of intake manifold pressure sender G71.
18. Loosen and unscrew 6 securing bolts for upper part of intake manifold . [Note: Natural gas system may not be operated until tested accordingly.]
19. ⚠ Operating the natural gas system without having tested it for leaks according to specifications may result in severe injuries or death.The necessary scope of the leakage test depends on the pressure section which has been worked on.Note the following allocation! — Open fuel tank shut-off valves N361/N362/N363/N429 (depending on vehicle model and equipment level) using hand wheel T50026.
20. Check gas system Checking natural gas supply system for leaks

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