[chittychittybangbang]

It's pretty much the same thing as the mk4 but the 1996 passat has no egr cooler.

The writeup can be viewed here:
http://www.myturbodiesel.com/1000q_how_to/a3b4/cleanintake.htm

The main challenge was that 2 of the allen bolts were rounded off....so I had to get a bolt out set.

 

[Fluid]

I think world impex sells a kit for the intake gasket, might want to add that to the parts section

 

[JohnPk]

Mine leaks too, I would think that if you used anything harsh on the whole manifold the EGR leak would get worse, depending on what it is made out of.

 

[chittychittybangbang]

IMO, use a brush and powerwasher. Biodiesel, brake cleaner, and carb cleaner works too. Make sure to get the corners and inside edges. I didn't soak the EGR part in solvent because I was worried about it.

I don't like sandblasting unless you can inspect the inside of the manifold. If they do a bad job cleaning it, it'll have some sand stuck inside that might go into the engine sooner or later.

 

[5point]

You can also try ultrasonic cleaning. It works great vs sandblasting.