2004-2005 VW Passat TDI "how to" index, BHW engine

Here is a DIY TDI FAQ for mk4 VW Passat TDI.  The mk4 was only sold 2004-2005 and with tiptronic transmission.

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.

Engine

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 are under recall)

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
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

BHW TDI engine timing belt - part 1- removal
TDI BHW engine timing belt - part 2- installation

Pumpe duse engine camshaft lobe wear inspection

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

Serpentine belt and AC belt removal on VW Passat TDI

alternator removal on VW Passat
testing the battery and replacement

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)

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

 

Drivetrain

Outer CV boot replacement and inspection (do you see grease sprayed on the inside of the wheels?)

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

sway bar and bushing replacement (to fix misc suspension noise)

Strut/shock removal and installation

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)

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

How to remove the glove box Passat and part numbers

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

Fuel filler door modification - lets it pop open further (Jetta shown but Passat is similar)

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 trim and steering wheel removal

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 TDI FAQ at 1000 answered questions: turbodiesel FAQ and general "how to" index


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