Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSVOLKSWAGEN2004PASSAT GL, 4D SEDAN, 2.0 E, AUTOMATICREPAIR AND DIAGNOSISENGINE MECHANICALEXHAUST2.0L 4-CYL 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE: BHW10 ENGINE - ASSEMBLYENGINE, REMOVING AND INSTALLINGNOTES ON INSTALLING
2004 Volkswagen Passat GL, 4D Sedan, 2.0 E, Automatic
Notes on installing
2004 Volkswagen Passat GL, 4D Sedan, 2.0 E, AutomaticSECTION Notes on installing
Installation is performed in the reverse sequence. Note the following:
CAUTION:
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
- Route all the various lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid, vacuum lines and hoses) and electrical wiring so that the original positions are restored.
- Ensure sufficient clearance to all moving or hot components.
Vehicles with manual transmission
- Check clutch release bearing for wear and replace if necessary.
- Lightly grease clutch release bearing and input shaft splines with G 000 100 (do not grease guide sleeve for release bearing).
- Needle bearing must be installed in driveshaft; install needle bearing if necessary → Crankshaft needle bearings, pulling out and driving in .
Vehicles with automatic transmission
- Fasten torque converter to drive plate using only original bolts.
- Before installing engine, turn torque converter and drive plate such that a hole is level with starter installation opening.
Continued for all vehicles
- Make sure intermediate plate is properly seated on engine.
- Make sure centering sleeves for engine to transmission are installed in cylinder block. Install if necessary.
- Replace self-locking nuts for securing engine mount.
- Align engine mount for stress-free installation through shaking movements.
- Install power steering pump: → 48 STEERING .
- Install ribbed belt → Ribbed belt, removing and installing .
- Install Motor for intake flap -V157-.
- Install connecting pipe between charge air cooler and Motor for intake flap -V157-.
- Fasten front exhaust pipe to turbocharger → Exhaust system components, removing and installing .
- Install starter: → 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- Electrical connections and routing: → 97 - WIRING
- Install air conditioning compressor: → 87 - AIR CONDITIONING
- Remove lock carrier with attachments: → 50 BODY, FRONT
- Install front bumper: → 63 BUMPER
- Install sound insulation pan: → 50 BODY, FRONT
- Fill with coolant.
- Check headlight adjustment and adjust if necessary:
- Adapt Engine Control Module (ECM) → Adapting functions and components .
- Test drive vehicle and check all Diagnostic Trouble Code (DTC) memories → Engine control module DTC memory, checking and erasing .
RENDER: 1.0x
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.