Gearbox removal & installation: VW Procedures for Passat 2.0 TDI (BKP, BMA, BMR, BUZ, …)

🧭 Before you start

Fits: VW Passat B6 (3C, 2005–2010)

• Opens: coolant
• Special tools named: VAS 5051, VAS 5052, T10012

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• The engine is lowered downwards with particulate filter fitted.
• To prevent damage to condenser or to refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
• To remove securing bolts, use stepladderVAS 5085.
• Engine with gearbox must be guided carefully when lowering to prevent damage to bodywork.

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📐 32 workshop diagrams for BKP

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Read fault memories of all control units before removal Diagnosis tester VAS 5051; Guided fault finding; Vehicle system test or VAS 5052; Vehicle self-diagnosis.
2. With ignition switched off, disconnect earth strap from battery 27.
3. Remove engine cover.
4. Remove bolt (arrow A) and pull air filter housing upwards out of mounting.
5. Remove air filter housing together with air mass meter and connecting pipe.

6. Disconnect all necessary vacuum lines or, when fitted, connectors on solenoid block .
7. Remove battery and battery tray.
8. Remove wiper arms 92.
9. Remove plenum chamber cover 64.
10. Release connector on engine control unit and pull it off .
11. Release connector on engine control unit and pull it off .
12. Remove feed-through for engine control unit wiring harness (arrow).
13. Open cable guide fasteners (arrows).
14. Remove wiring harness from cable guide on longitudinal member and lay to side on engine.
15. Pull off fuel supply hose (2), fuel return hose (1) and coolant hose (3).
16. ⚠ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure!Wear eye and hand protection when performing any type of repair work on the fuel system! — Remove wire from central electrics (arrow).
17. Unscrew earth cable (arrow) from longitudinal member.
18. Move wiring clear.
19. Pull off or disconnect all other electrical connections from engine and gearbox as necessary and lay to side.
20. Separate all connecting, vacuum and intake hoses from engine.
21. Disconnect gear selector mechanism from gearbox 6-speed manual gearbox 02Q34Repairing gear selector mechanism.
22. Disconnect gear selector mechanism from gearbox 6-speed manual gearbox 02Q, four-wheel drive34Repairing gear selector mechanism.
23. Remove slave cylinder for hydraulic clutch or, disconnect line at slave cylinder 30.
24. Remove noise insulation tray 50.
25. Pull connector off oil level and oil temperature sender G266.
26. Pull retainer for oil level and oil temperature sender G266 wiring harness off subframe.
27. Drain coolant .
28. Bring lock carrier into service position 50.
29. Completely remove exhaust pipes from supplementary heater 82.
30. Pull coolant hoses off supplementary heater.
31. Separate all other coolant hoses from engine.
32. Remove right drive shaft and disconnect left drive shaft from gearbox 40.
33. Remove front propshaft Final drive 02D, 0AV39Assembly overview - repairing propshaft.
34. Release connecting clamp for front exhaust pipe/front silencer.
35. Remove subframe and steering Running gear, axles, steering40. [Note: The engine is lowered downwards with particulate filter fitted.]
36. Disconnect front exhaust pipe from turbocharger, loosen double clamp and remove exhaust pipe .
37. Unbolt pendulum support (arrows).
38. Remove poly V-belt .
39. Separate air conditioner compressor from compact bracket 87.
40. Secure air conditioner compressor to lock carrier so that refrigerant lines are free of stress. [Note: To prevent damage to condenser or to refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.]
41. Fit engine bracket T10012 onto cylinder block with securing nut and M10×25/ 8.8 bolt and tighten to approx. 40 Nm. — 40 Nm (30 lb-ft)
42. Insert engine bracket T10012 in engine and gearbox jackV.A.G 1383/A.
43. Lift engine and gearbox lightly using engine and gearbox jackV.A.G 1383/A. [Note: To remove securing bolts, use stepladderVAS 5085.]
44. Unbolt engine side of assembly mounting from engine support from above (arrows).
45. Unbolt gearbox side of assembly mounting from gearbox bracket from above (arrows).
46. Carefully lower engine with gearbox. [Note: Engine with gearbox must be guided carefully when lowering to prevent damage to bodywork.]

Other VW procedures

• Checking current draw of fuel pump – VW Golf V / Jetta
• Cleaning unit injectors (engine codes BMN, BKP, BMA, BUZ and BMR)
• Checking for internal leaks – VW Touareg I
• Checking oil pressure switch – VW Golf IV / Bora
• Renewing spur gear for crankshaft – VW 2.0 TDI
• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures