As we know the engine bay area of the 2001-2005 VW Passat is very tight and challenging to perform any repairs. This article will discuss how to remove the front bumper cover and put your VW Passat into the service position. This will allow more space surrounding the engine. Typically, this service position is necessary to perform the timing belt replacement and other in-depth part replacements on the front side of the engine.
How To Put A VW Passat Into Service Position
Applies to the following Volkswagen Passat service position
- 2001-2005 VW Passat Models (B5.5 Chassis)
DISCLAIMER: Blauparts recommends that an Audi VW Factory Trained ASE Certified Technician perform the repair.
Always read the factory service manual safety instructions and guidelines. Always wear safety glasses and other safety items when performing the following repair.
How To Step 1
Elevate the vehicle on an automotive lift or jack stands, using proper lift points as outlined in the owner's manual.
Remove the lower splash pan.
How To Step 2
Remove the lower driver and passenger 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 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 grill until the grill's lower mounting tabs pop out.
How To Step 5
With the main grille removed, locate and remove the (4) Torx screws found in lower grille cavity.
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 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 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 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 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 Step 12
Locate and remove (2) fasteners holding the fender to the radiator valance, one fastener found under each headlamp.
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 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 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.