2004 2005 VW Passat TDI FAQ and DIY list

[chittychittybangbang]

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, 2010

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, 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 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)
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
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 how tos at 1000 answered questions: turbodiesel FAQ and general "how to" index