VW Passat Front Bumper Removal Instructions for 1.8T 20 Valve Engine

BACK TO >> 1.8T VW Passat Timing Belt Information Table of Contents

How To Put A VW Passat Into Service Position
2001-2005 Models

DISCLAIMER: Blauparts recommends that an Audi VW Factory Trained ASE Certified Technician perform repair.

Always read the factory service manual safety instructions and guidelines. Always wear safety glasses and other safety items when performing the following repair.

NOTE: The following bumper cover removal instructions are the newer Passat B5 platform (aka B5 with updated front end or B5.5). However, the basic procedures are very similar and partially apply to the earlier 1998-2001 B5 platform.

All information and images © copyright of Blaufergnugen Inc.

How To Step 1

Elevate vehicle on an automotive lift or jack stands, using proper lift points as outlined in the owners manual.

Remove the lower splash pan.

How To Step 2

Remove the lower drivers and passengers side bumper grilles. Reach in behind the fog light and unplug the electrical connectors.

How To Step 3

Remove the main hood latch mechanism by removing the (3) 10mm fasteners and the electrical plug.

Additionally, remove the secondary hood release lever. Pry up and remove the spring clip from the hood latch lever, then use a flat blade screwdriver to spread the latch apart so that the rod clears the latch pins. Next, remove the latch and place it off to the side.

How to remove the bumper - VW Passat service position - Step 3
How to remove the bumper - VW Passat service position - Step 3b

How To Step 4

Remove the main grille by removing (2) Torx head fasteners, one located at each side of the grille. Firmly pull up on the grille until the grilles lower mounting tabs pop out.

How to remove the bumper - VW Passat service position - Step 4
How to remove the bumper - VW Passat service position - Step 4b

How To Step 5

With the main grille removed, locate and remove the (4) Torx screws found in lower grille cavity.

How to remove the bumper - VW Passat service position - Step 5

How To Step 6

Locate and remove the fasteners located on the forward side of each wheel well. You will find a total of (4) fasteners in each wheel well, with one being rather hidden toward the very top of each wheel well as pictured.

How to remove the bumper - VW Passat service position - Step 6

How To Step 7

Remove the bumper cover by firmly pulling the cover forward, one side at a time. While pulling the bumper cover forward, you will need to unplug the electrical connectors for the amber side indicator lamps, found on each side of the bumper.

How to remove the bumper - VW Passat service position - Step 7

How To Step 8

Locate and remove the (5) fasteners that hold the upper plastic bumper cover reinforcement, also the (2) fasteners holding the lower steel bumper cover reinforcement.

How to remove the bumper - VW Passat service position - Step 8

How To Step 9

Remove the upper outer fasteners from the bumper shock brackets on each side of vehicle, replace fasteners with special tool 3411. Once installed, remove all remaining fasteners from bumper shock brackets.

How to remove the bumper - VW Passat service position - Step 9

How To Step 10

Remove the (2) fasteners that hold the air box intake tube in place, then pull upward on intake tube to completely remove it.

How To Step 11

Remove the upper radiator valance fastener located at the forward fender edge on each side of vehicle.

How to remove the bumper - VW Passat service position - Step 11

How To Step 12

Locate and remove (2) fasteners holding the fender to the radiator valance, one fastener found under each headlamp.

How to remove the bumper - VW Passat service position - Step 12

How To Step 13

Locate the radiator drain screw at the lower front driver side of the radiator. Drain the coolant from the system into a suitable drain pan.

How to remove the bumper - VW Passat service position - Step 12

How To Step 14

Drain the coolant out of the radiator by opening the drain screw found on the lower
drivers side of the radiator.

How to remove the bumper - VW Passat service position - Step 13

How To Step 15

Remove the lower intercooler hoses from the intercooler crossover pipe.

How To Step 16

Remove the upper and lower radiator hoses by gently prying on the removal clip
integrated into the hose clamp with a screwdriver blade.

How To Step 17

Slide entire radiator and front support assembly forward on the pair of previously
installed special tool 3411.

All information and images © copyright of Blaufergnugen Inc.