How to Replace the Throttle Body in a VW Passat

Written by ehow cars editor
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Volkswagen Passat is a favorite among new car shoppers who are looking for a bit more luxury and style than offered by the average family sedan. Considered a "stepping stone" for the fans of German luxury cars, the Passat has an impressive and loyal following. The following do-it-yourself steps guide you through the installation of a new throttle body.

Skill level:

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Things you need

  • Mechanic's toolset, including a full socket set, wrenches and screwdrivers
  • Torque wrench
  • Clean shop cloths
  • Replacement gasket

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    Remove the Throttle Body

  1. 1

    Make sure the engine and all components are completely cool. Disconnect the battery ground and then isolate it to avoid accidental contact with the terminal while installing the throttle body. Drain the engine coolant.

  2. 2

    Disconnect the air intake duct and set it to the side to allow access to the throttle valve housing. Disengage the wiring harness the throttle position sensor and then take the accelerator cable out of the housing.

  3. 3

    Take off the expansion tank filler cap found on the VR6 engine. Clamp the coolant hoses to prevent the leakage of coolant, then remove them from the throttle body. Remove the Evaporative Emissions hose from the throttle body on four-cylinder engines.

  4. 4

    Loosen the retainers that secure the throttle body to the intake manifold. Lift off the throttle body, pull the gasket and dispose of it. Place a clean shop cloth over the opening on the manifold to prevent debris from falling into the engine.

    Install the Throttle Body

  1. 1

    Clean any old gasket material, carbon deposits and debris from the gasket mating surfaces on the throttle body and the manifold.

  2. 2

    Place a new gasket on the throttle body. Install the throttle body to the manifold. Transfer all sensors when the housing is being replaced along with the throttle body.

  3. 3

    Reconnect the EVAP vent hose on the four-cylinder engine. Reconnect the coolant hoses to the throttle body on the VR6 and then remove the clamps.

  4. 4

    Attach the accelerator cable to the throttle valve. Reconnect the TSP wiring harness. Set the air intake duct in position.

  5. 5

    Refill the engine coolant with the proper type and mix. Reconnect the battery ground cable.

  6. 6

    Start the engine and check for leaks and make the necessary adjustments. Check the coolant level and add as needed.

Tips and warnings

  • Take care not to damage the surfaces with sharp instruments.
  • Dogs, cats and farm animals will drink coolant that is left in open containers or pooled on the floor; ingestion is usually fatal. Reuse coolant unless it is contaminated or old.
  • Never smoke or expose an open flame of any kind to the area near fuel-related engine parts.

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