Question about 2002 Volkswagen Passat
The pulley and part of the metal frame broke off while driving. The metal is broken. How do you replace the pulley assembly?
Find the bolts attaching the bracket to the engine (possibley2 or 3) Buy a genuine replacement assy and fit get a new belt as the old one may have suffered damage. Replace where you removed the broken bit and adjust the belt to the correct tension
Posted on Jan 11, 2013
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Posted on Jan 02, 2017
Oops, sorry about that.....
The power steering fluid reservoir is located just behind the drivers (LHD) headlight, just forward of the washer fluid reservoir.
The reservoir has a green cap on it and a plastic trim panel to conceal the sides, it is circled here:
Posted on Sep 20, 2009
Testimonial: "I found this information extremely useful, including that picture describing it..... wow Thank you very much"
get a complete regulator from vw or check fcp groton .com i am a vw tech you will be there forever if you try the cable you will never get it wound around regulator leaving you with a window that doesnt work
Posted on Jul 23, 2009
Yes you can repair the thermostat by yourself, I have done it. Assuming that you have a V6, because you did not say if it was a 4 cyl or 6 cyl. If it is a 4 then it will be easier, and the thermostat is on the driver side at the bottom of the water pump housing.
A V6 does require that you place the front panel & radiator into service position. To do this you need to remove the plastic engine cover under the car, and the plastic in front of the wheels in the well. Now, the hood release must be detatched. The power steering hose that runs to the bottom of the radiator set to the side, but not removed. The front of the car is going to come off, and the bumper. Drain the radiator, and disconnect the two hoses at the top next to the spill over resevoir.
The manual says to use two long dowels to support the radiator and its support panel, but I found that a floor jack works best, and since you do not really need to raise the car for this job, I find it easier not to. Just open the panel from one side, and leave the air conditioning side all connected. This will give you lots of room to work with. It make take you a little bit at first, but you will get fast at it. This is how you work on this car with tons of space.
The thermostat is on the front of the engine block, inside the hose, just pull the hose off, and remove a few bolts on the cover. Make sure you have a new O-ring to go with that thermostat.
No doubt that getting the car into service position, with the radiator panel away from the car, but it allows for you to get your tools in with leverage. Unfortunately, this job would be a snap if it were not for the fact that you have to put it in service position, nut other jobs it will help. You will need to take off the drive belt for this job, for access. It is not a problem, just replace it while you are there, if it is worn at all.
This job will take me 3 hrs, and I have done it many times, but I am slow. Be prepared to work all weekend if you dont have a manual to follow. They can reveal every screw and bolt.
Posted on Jan 31, 2010
Testimonial: "Very helpful"
Belt routing diagram for 1997 VW Passat 1,9 TDI:
CS = Crankshaft
F = Fan pulley
Gen = Alternator
T = Tensioner
AC = Air Conditioning
PAS = Power Assisted Steering
WP = Water Pump
Posted on Jul 13, 2010
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