2004 2005 VW Passat TDI FAQ and DIY list

Discussion in 'VW Mk4 Jetta, Golf, New Beetle, Passat TDI forum' started by chittychittybangbang, Oct 4, 2009.

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  1. chittychittybangbang

    chittychittybangbang Administrator

    May 23, 2007
    2006 Jetta TDI
    B5.5 "how to" index for 2004-2005 VW Passat TDI BHW 2.0L turbo diesel engine tiptronic transmission
    The blanks will get filled in as I finish the articles, please check back for updates! Last updated Sept 15, 2013

    Did you just buy a Passat TDI or are you looking for one? See 1000q: new Passat TDI owner checklist for a list of common problems, quirks, and immediate maintenance.


    Removing the front bumper or putting the lock carrier in the service position or remove it
    Hard or no starts in cold temperatures after having the glow plug recall done
    Engine oil drain and oil filter change 2004 2005 VW Passat TDI (every 10,000 miles)
    Fuel filter change and interval (drain water every 10,000 miles, replace every 20,000 miles)
    Glow plug removal, recall, and How to do an engine compression test on your TDI (Bosch ceramic plugs were under recall)
    Stripped glow plug thread repair
    Splash shield removal and fastener parts list (for gasser and diesel VW Passat)
    Oil pump/ balance shaft/ chain noise/ rattling engine noise FAQ - TDI engine only part 1- background and technical information
    TDI engine inspection and repair of failed oil pump
    (part 2 - goes beyond only balance shaft assembly replacement)
    Balance shaft assembly and oil pump replacement with OEM gear drive assembly - part 1
    - introduction and lowering the subframe
    Balance shaft assembly and oil pump replacement - part 2 - oil pan and balance shaft assembly removal, exclusive content, please join our forums to view
    BHW TDI engine timing belt - part 1- removal
    TDI BHW engine timing belt - part 2- installation
    (exclusive content, please join our forums to view)
    Pumpe duse engine camshaft lobe wear inspection
    How to remove PD TDI fuel injectors (please join our forums to view)
    How to remove PD TDI fuel inj #2

    How to fix a rough idle or hard start caused by camshaft timing
    Water pump removal and replacement (can solve mystery overheating)
    Thermostat replacement on Passat
    How to do a coolant flush, bleed radiator, or drain coolant on Passat (air can become trapped in the heater core, sloshing sound after engine start)
    Serpentine belt and AC belt removal on VW Passat TDI
    alternator removal on VW Passat
    testing the battery and replacement

    Alternator troubleshooting, pulley replacement, and voltage regulator repair
    Battery part number reference
    Starter removal and won't start or crank diagnostics
    AC condenser compressor removal
    VW Passat engine and transmission removal
    Downpipe or O2 sensor replacement and removal
    intake manifold and EGR removal
    Engine air filter replacement
    Motor mount replacement (if you see red stains under them they're bad)
    Fuel tank venting (lets you put in a few more gallons of fuel per tank)
    How to repair broken plastic vacuum nipple
    Engine runaway FAQ (rare problem where the engine races on its own due to mechanical malfunction)
    Immobilizer FAQ (anti theft system)
    mk4 VW key FAQ, battery replacement, and key replacement


    Inner, outer CV boot and joint replacement and axle removal (do you see grease sprayed on the inside of the wheels or have vibration at idle that goes away in N?)
    Automatic tiptronic transmission fluid drain and filter change - for 01v 5 speed, also how to replace fluid in the torque converter
    Transmission mount replacement and alignment

    Tire / Wheel / gearing calculator

    Tire and wheel size calculator - also does wheel clearance, offset, and final drive gearing calculations

    Brakes and suspension

    Brake master cylinder / brake booster removal on VW Passat
    How to bleed brakes and get out air bubbles on VW Passat (every 2 years or as needed)
    Front brake job
    rear brake job and rear wheel bearing removal Passat
    Control arm replacement, tie rod end replacement, or steering knuckle removal
    Inner and outer tie rod end replacement
    sway bar and bushing replacement (to fix misc suspension noise)
    Rear shock and spring removal/installation, also heavy duty towing spring modification
    Power steering fluid, power steering pump, and steering rack change removal
    How to remove the Volkswagen Passat steering wheel.

    Car Detailing

    Car detailing index: wash and wax the proper way, polishing paint, using rubbing compound, clay bar treatment
    Washing/waxing your car - yes, there is a right way
    Polishing your paint/swirl mark removal - enhance paint shine and remove paint spiderwebbing
    Clay bar treatment - make the paint feel like glass
    Sticker removal - safely remove that sticker from the paint
    Headlight polishing - restore the headlight plastic to clear
    Wax stain removal - remove white stains on the trim
    Paint chip repair
    Small scratch removal

    Misc., body, interior

    Door lock module removal (if your interior light doesn't come on when you open the driver door)
    VCDS (ross tech vagcom) mods, tricks, and settings - These can disable auto-unlock of the doors above 10 mph, unlock all doors with one press of the remote, or adjust the horn/light blinking when locking/unlocking the car.
    window regulator repair and window motor replacement, and window clips
    Door card removal on mk4 B5 VW Passat and B5.5 Passat (also shown is side view mirror removal)
    What the part numbers mean and how to decode the Volkswagen/Audi part numbers with ETKA
    How to swap in power and/or heated seats
    How to remove the seats or the CCM or automatic transmission ECU
    iPod adapter and aux-in information (only for OEM parts since there are so many aftermarket)
    How to remove the glove box Passat and part numbers
    Clicking turn signal relay repair and hazard switch relay replacement (turn signals not working)
    How to remove the center console or shifter knob
    Tips and tricks for the mechanic
    cabin air filter replacement
    Jack points to raise my 2005 VW Passat
    How to fix shaking headlights - most noticeable when at a stoplight
    Dashboard camera (dashcam) hardwire installation
    Fuel filler door modification - lets it pop open further (Jetta shown but Passat is similar)
    How to replace the tail light bulbs
    fender removal
    Mudflap installation
    Making wood blocks to raise the car
    Blind spot mirror or side view mirror replacement
    Turn signal replacement, side view mirror replacement, or side view mirror cover removal
    grille modification for more air intake
    misc lower dashboard trim and steering column trim removal
    How to remove the ignition switch and lock cylinder
    How to use a torque wrench and torque wrench FAQ
    Adding soundproofing to the TDI and introduction to soundproofing theory
    Clearing the sunroof drains to prevent water in the interior
    Ecode headlights - what are they and how do you use them (for the mk4 generation but the same idea)
    DRL daytime running light disable
    Adding HID headlights to the projector headlight on VW Passat

    How to change the H7 headlight bulbs on VW Passat
    How to remove the side marker light bulb (or remove the light)
    Fender rolling to fit larger wheels
    MK3 vs MK4 generational differences - 3rd vs. 4th gen differences and interchangeable parts
    OEM VW/Audi wheel gallery, part numbers, and specs
    light bulb replacement reference table
    Wheel alignment specifications table
    Touch up paint code reference table

    More how tos at 1000 answered questions: turbodiesel FAQ and general "how to" index
    CasperDiesel and fasteddie like this.
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