VW Passat B5 (1996–2005) How to Remove Bumpers

The Volkswagen Passat B5 is the fifth generation of the popular sedan and station wagon, produced from 1996 to 2005. This model marked a significant step forward for Volkswagen, introducing a platform shared with Audi, along with a more modern design and improved performance.

Production Years and Facelift

The Passat B5 debuted in 1996, replacing the previous B4 generation. In 2000, the model underwent a facelift (often referred to as B5.5), which brought updates to the exterior, interior, and technical specifications. Key changes included:

• A new front end with complex-shaped headlights.
• A revised radiator grille.
• An updated dashboard and multimedia system.
• Improved engines, including the introduction of pump-injector turbo diesels (PD-TDI).

Production of the Passat B5 ended in 2005 when it was succeeded by the sixth generation (B6).

 

Model Codes and Platform

The Passat B5 was built on the Volkswagen Group PL45 platform, which was also used for the Audi A4 (B5). This gave the model a multilink front suspension (instead of the MacPherson struts used in the B4) and enhanced handling.

Main body codes:

• 3B2 – Sedan (1996–2005).
• 3B5 – Variant station wagon (1997–2005).

 

Body Types and Modifications

The Passat B5 was available in two body styles:

• Sedan – A classic four-door version.
• Variant (Wagon) – A more practical version with increased trunk space.

 

Engines and Transmissions

The model was equipped with a wide range of gasoline and diesel engines:

Gasoline:

• 1.6L (101 HP) – Base naturally aspirated engine.
• 1.8L (125 HP, 150 HP with turbocharging) – The most popular option.
• 2.0L (115 HP).
• 2.3L VR5 (150 HP) – An unusual 5-cylinder engine.
• 2.8L VR6 (193 HP) – A powerful 6-cylinder version.
• 4.0L W8 (275 HP) – An exclusive 8-cylinder variant (2001–2004).

Diesel:

• 1.9L TDI (90–130 HP) – Reliable and fuel-efficient.
• 2.5L V6 TDI (150–163 HP) – The most powerful diesel in the lineup.

Transmissions:

• 5- and 6-speed manual gearboxes.
• 4- and 5-speed automatic transmissions (including Tiptronic).
• 4Motion all-wheel drive (available on select models).

 

Bumper Plastic Markings: >PP+EPDM-T10< or >PP/EPDM/PE<

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How to Remove the Front Bumper

1. Open the hood.
2. Release the hood latch lever. Lift the metal latch retainer and use a flat screwdriver to bend the lever ends outward.

For 1997–2000 models:

• Unscrew the four screws (fastened top to bottom) securing the radiator grille.
• Remove the turn signals (press the plastic spring-loaded clips from the engine bay side, then pull the turn signals forward).
• Unscrew the two screws beneath them.

For 2000–2005 models:

• Unscrew the two screws, release the clips, and remove the radiator grille.
• Under the grille, unscrew four screws (fastened top to bottom) securing the upper part of the front bumper.

3. Turn the wheels to the side.
4. In the wheel arches, unscrew three screws on each side securing the fender liners (front part).
5. Behind the liners, unscrew one screw on each side (fastened bottom to top) securing the bumper corners to the fenders.
6. From underneath, unscrew three screws (fastened bottom to top) securing the engine compartment shield.
7. With an assistant, pull the front bumper forward off the guide brackets in the fenders.
8. Disconnect the wiring harnesses and headlight washer hoses (if equipped).

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How to Remove the Rear Bumper

For Sedan (2000–2005):

• Open the trunk lid.
• Open the side trim covers inside the trunk and unscrew three nuts on each side, then remove the taillights.
• Under the taillights, unscrew two screws on each side.

For Sedan (1997–2000) and Wagon (1997–2005):

• Open the trunk (or tailgate) and unscrew two (or four in the wagon) screws in the trunk opening.

1. In the wheel arches, unscrew three screws on each side securing the bumper to the fender liners.
2. From underneath, unscrew five (or seven, depending on body type) screws (fastened bottom to top).
3. Release the clips in the fenders (pull backward and outward).
4. With an assistant, pull the bumper rearward (watch for wiring).
5. Disconnect the wiring harnesses (if equipped).

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Model Overview

The Passat B5 featured a restrained yet elegant design typical of Volkswagen in the late 1990s and early 2000s. The interior used high-quality materials, and noise insulation was better than many competitors.

Advantages:

• Good handling thanks to the multilink suspension.
• Spacious cabin and trunk.
• Reliable TDI diesel engines.

Disadvantages:

• Some gasoline engines (e.g., 1.8T) were prone to oil consumption issues.
• Body corrosion in cold climates.

 

Interesting Facts

• Passat W8 – The most unusual version with an 8-cylinder W-engine and all-wheel drive. Produced in limited numbers and not commercially successful.
• Passat B5.5 R-Line (2004–2005) – A sporty version with aggressive body kit, sport suspension, and a 2.8L VR6 engine.
• In China, the Passat B5 was produced until 2011 as the Volkswagen Passat Lingyu with minor changes.
• In North America, it was sold as the Volkswagen Passat (1998–2005) with some design and trim differences.

 

Conclusion

The Volkswagen Passat B5 is an important model in the brand’s history, combining German quality, advanced technology, and practicality. Despite its age, many examples remain on the road, especially diesel versions. The B5.5 facelift made the car even more appealing, while rare variants (W8, VR6) are sought after by collectors.