VW Passat Front Bumper Removal Instructions for 2.8L 30 Valve Engine

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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.

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.
  • Questions & Answers (3)
  • September 29, 2016
    Question/Comment from:
    Dana L
    how likely is it that you will have to replace the camshafts themselves? I have been told that when the timing belt goes that it will warp or bend the camshafts and or the pistons....is this actually the case?
    Answer from Huri of the blauparts technical team:
    When a Audi or VW timing belt breaks with an interference engine, several factors will need to be considered. Just because the valves strike the pistons does not always mean all valve train or piston components are bad. Upon disassembly of the engine the crowns of the pistons, valves, and camshafts can be inspected. You should be able to blatantly see markings as to which piston struck valves. Many times only a few of the cylinders will have catastrophic damaged (ie: piston, valves, camshaft). This is dependent on how the engine was being used at the time of the timing belt break. Inspect the crowns of the pistons for cracks or imperfections. If imperfections are visible in the piston that struck valves, the piston should be replaced. When it comes to the camshafts, many times only the camshaft that had valve strike should be inspected and replaced if needed. However I would strongly recommend some one with extensive Audi or VW engine assembly experience inspect your engine for the best results. In most cases it is always good to perform your Audi or VW timing belt and timing belt tensioner changes at an interval slightly sooner then the factory recommended interval. This is always more cost effective. If you have any other questions feel free to contact us. Thanks!
  • May 29, 2015
    Question/Comment from:
    Brian G
    How To Step 15 Remove the lower intercooler hoses from the intercooler crossover pipe. Why are we removing an intercooler hose from a normally aspirated engine ?
    Answer from Jim of the blauparts technical team:
    The bumper removal applies to both 2.8L V6 (naturally aspirated) and the 4 cylinder 1.8L Turbo that does have the inter cooler hoses.
  • October 14, 2014
    Question/Comment from:
    Kato L
    hi there, can you tell me where i can get this special tool 3411 you speak of? What is it?
    Answer from Huri of the blauparts technical team:
    This the special tool 3411 is included in our timing belt tool rentals. Select your vehicle on this page http://www.blauparts.com/products.asp?cat=579
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