service VOLKSWAGEN PASSAT 2006 Repair Manual

Checking the vehicle battery acid level
x If the lighting conditions are poor, use a flashlight so that you can clearly see the battery acid level indicator and tell what color it is. Never use an open flame or an unprotected light source.
x The round battery window (“acid level indicator”) on the top of the battery changes color, depending on the battery's electrolyte level.

Color indication Action
Light yellow or colorless Battery electrolyte level is too low. The vehicle battery may need to be replaced. Have it checked by an authorized Volkswagen dealer or an authorized Volkswagen Service Facility.
Black Battery electrolyte level is satisfactory.
WARNING
Working on the batteries can cause serious acid burns, explosion, or electrical shock.
x Always wear eye protection and protective gloves.
x Sulfuric battery acid is very corrosive. It can burn unprotected skin and cause blindness. Always wear protective gloves and eye protection.
x Never tilt the vehicle battery. Acid could spill out of the battery vents and burn you.
x Never open a vehicle battery.
x If you get battery acid in your eyes or on your skin, immediately rinse with cold water for several minutes and then get immediate medical attention.
x If you swallow any battery acid, get medical attention immediately.
Charging, replacing, disconnecting and connecting the vehicle battery

x First disconnect the negative cable (-) and then the positive cable (+) ⇒ .
Connecting the vehicle battery
x Prior to reconnecting the battery, switch off all electrical systems and devices and the ignition.
x Connect the positive cable (+) first and then the negative cable (-) ⇒ .
After the battery is connected and the ignition is switched on, different indicator lights may come on. They should go out after you drive a short distance at 10–12 mph (15–20 km/h). If the indicator lights do not go out , contact an authorized Volkswagen dealer or an authorized Volkswagen Service Facility and have the vehicle checked.
If the battery was disconnected for a long time, the next scheduled service may not be correctly
calculated and displayed ,Instrument cluster The maximum permissible service and maintenance
intervals are shown in the ⇒ booklet Warranty and Maintenance.
Vehicles with Keyless Access
If the ignition will not start after reconnecting the vehicle battery, lock the vehicle from the outside and unlock it again, Unlocking and locking vehicles with Keyless Access. Then try to start the ignition again. If the ignition cannot be switched on, contact an authorized Volkswagen dealer, an authorized Volkswagen Service Facility, or another qualified workshop for assistance.
Automatic electrical load deactivation
If the vehicle battery drain is high, the intelligent onboard electrical system management automatically takes steps to help prevent battery drain.
x The idle speed is increased so that the alternator provides more power.
x The power to devices that consume a lot of electricity is cut back or switched off completely.
x When the engine is started, the power supply to the 12 Volt sockets and the cigarette lighter, Cigarette lighter is temporarily interrupted.
The onboard electrical system management cannot always keep the battery from being drained. For example, the battery will drain if the engine is not running, but the ignition is switched on or the parking lights are left on for a long time when parked.
Battery disconnection in an accident with airbag deployment
In vehicles with a battery in the luggage compartment, the electrical connection to the battery is disconnected automatically in a collision with airbag deployment. This helps to prevent a short-circuit.
What drains the vehicle battery?
x Long periods when the engine is not running, especially when the ignition is on.
x Using electrical systems or devices when the engine is switched off.
x Leaving the vehicle unlocked for several days when not in use.
x The selector lever is left for a long period of time in any position other than P when the ignition is switched off, Automatic transmission: Selector lever.
WARNING
Failure to use the proper battery with proper mounting and connections may cause short circuits, fires, and serious personal injuries.
x Always use only maintenance-free or cycle-free, leak-proof batteries with the same specifications and dimensions as the original equipment battery. Specifications are listed on the battery housing.

Check all wiper blades regularly. Wiper blades that grab and squeak must be replaced if worn or
damaged and cleaned if dirty ⇒ .
Replace worn or damaged wiper blades immediately. Replacement blades may be purchased from any authorized Volkswagen dealer or authorized Volkswagen Service Facility.
Lifting and tilting windshield wiper arms
Move the wiper arms to the service position before lifting them away from the windshield Windshield wiper and washer.
It is not possible to lift the wiper arms away from the windshield when they are not in the service position.
When lifting or replacing a wiper blade on a window, grip it only by its mounting and not by the blade itself.
Cleaning the wiper blades
x Lift the wiper arm(s) away from the windshield.
x Using a soft cloth, carefully remove dust and dirt from the wiper blades.
x If the blades are very dirty, carefully clean them with a sponge or cloth ⇒ .
x Carefully fold the wiper arm back down onto the windshield.
Changing wiper blades
x Lift the wiper arm away from the windshield.
x Press and hold the release button ⇒ fig. 187 (1).
x While lifting the wiper blade in the direction of the wiper arm, pull off the wiper blade in the direction of the arrow. This may require moderate force.
x Install a new wiper blade of same length and type onto the wiper arm by pushing in the opposite direction of the arrow until it latches.
x Carefully fold the wiper arm back down onto the windshield.
WARNING
Worn or dirty wiper blades reduce visibility and increase the risk of accidents and severe injuries.
x Always change wiper blades if they are damaged or worn, and if they cannot clean the windows sufficiently.
NOTICE
x Damaged or dirty wiper blades can scratch the windshield.
x Solvents, abrasive sponges and sharp-edged objects will damage the graphite coating on the wiper blades.
x Do not clean the windows with gasoline, nail polish remover, paint thinner or similar fluids.
x To help prevent damage to the engine hood and the windshield wiper arms, lift the wiper arms away from the windshield only when they are in the service position.
Waxing and polishing vehicle paint

WARNING
Improper care and cleaning of vehicle components can compromise the vehicle's safety features and cause serious personal injury.
x Always clean and maintain vehicle components according to manufacturer's instructions.
x Only use approved or recommended cleaners.
NOTICE
x Vehicle care products containing solvents can cause irreparable damage to plastics and other vehicle materials.
x Stains, dirt and other deposits that contain aggressive substances or solvents can corrode vehicle materials and cause permanent damage, even after brief contact with the surface.
x Remove stains, dirt, and other deposits as quickly as possible and do not allow them to dry.
x To help prevent damage, have stubborn stains removed by a professional who has the necessary expertise and experience.
Suitable care products are available from authorized Volkswagen dealers and authorized Volkswagen Service Facilities.
Caring for upholstery

Removing stains
When treating stains, it may be necessary to clean entire surface and not just the stain itself. This is especially true if the entire surface has become dirty from normal use. Otherwise, the area that is treated may be lighter than the untreated area. If you have questions or concerns, consult a professional cleaner.

Type of stain Recommended cleaning for fabric and upholstery
Water-based stains, such as coffee or fruit juice. – Moisten a sponge with water and rub the stain gently with a circular motion. – Wipe dry with an absorbent cloth.
Persistent stains, such as chocolate or make-up. – Use only Volkswagen-approved cleaning products. – If necessary, have the fabric or upholstery professionally cleaned.
Grease-based stains, such as oil, lipstick, etc. – Use only Volkswagen-approved cleaning products. – If necessary, have the fabric or upholstery professionally cleaned.
WARNING
If there is a malfunction in the airbag system, the airbag may not deploy correctly or at all, or it may deploy unexpectedly. This could cause fatal injuries.
x Have the airbag system inspected immediately by your authorized Volkswagen dealer or authorized Volkswagen Service Facility.
NOTICE
If the upholstery on power seats, heated seats, or seats with airbag components is wet, electrical components and the vehicle electrical system could be damaged.
x If the seating surface becomes soaked, have it dried and the system components checked immediately by an authorized Volkswagen dealer or authorized Volkswagen Service Facility.
x Do not use steam cleaners because the steam could cause the dirt to penetrate deeper into the fabric and make it impossible to remove.
x Pressure washers and cooling sprays can damage the upholstery.
NOTICE
x Clean only the carpet and floor mats with brushes. Other textile surfaces can be damaged by brushes.
x If detergent pastes or mild detergent solutions are applied with a damp cloth or sponge, the surfactants in the detergent may cause visible lines to form at the edges of the area where the detergent was applied. These lines are generally difficult or impossible to remove.
NOTICE
x Do not soak Alcantara®.
x Do not treat Alcantara® with leather care products, solvents, floor wax, shoe polish, stain remover or similar products.
x Do not use brushes for damp cleaning, because they can damage upholstery surfaces.
x Do not use a steam cleaner, because dirt will penetrate deeper into the fabric.

WARNING
Damage to safety belts reduces their overall effectiveness and increases the risk of serious personal injury and death whenever the vehicle is being used.
x Check the condition of all safety belts regularly. If you notice that the safety belt webbing, hardware, retractor, buckle, or any other part of the safety belts is damaged, immediately have an authorized Volkswagen dealer or authorized Volkswagen Service Facility replace the safety belt with the correct replacement belt for your vehicle model and model year.
x Never use chemical cleaning agents, solvents, or any substance that may damage or weaken the safety belt webbing or any other parts of the safety belt. Never let the belts come into contact with corrosive fluids or sharp objects. Otherwise, the safety belt webbing will be significantly weakened.
x After cleaning, always give the safety belts time to dry completely before letting them retract. The moisture can damage the retractor and keep it from working properly.
x Never let foreign objects or liquids get into the safety belt latch. This could prevent the belt buckles and safety belts from working properly.
x Damaged safety belts must be replaced; they cannot be repaired.
x Never try to repair a damaged safety belt yourself. Never remove or modify the safety belts in any way.
x Safety belts that were subject to stress in an accident and stretched must be replaced with a correct, new safety belt, preferably by an authorized Volkswagen dealer or authorized Volkswagen Service Facility.
x Replacement after a crash may be necessary even if a safety belt shows no visible damage. Anchorages that have been loaded must also be inspected.

WARNING
Inappropriate spare parts and accessories as well as unprofessionally performed work, modifications and repairs can cause vehicle damage, accidents and serious personal injuries.
x Volkswagen strongly recommends to only use accessories approved by Volkswagen and Genuine Volkswagen Parts®. These parts and accessories have been evaluated by Volkswagen for their suitability, reliability and safety.
x Have repairs and vehicle modifications performed by an authorized Volkswagen dealer or authorized Volkswagen Service Facility. Authorized Volkswagen dealers and authorized Volkswagen Service Facilities have the required tools, diagnostic equipment, repair information, and trained personnel to properly replace any airbag in your vehicle and assure system effectiveness in a crash.
x Only install parts on the vehicle that are consistent with factory-installed parts with respect to design and characteristics.
x Never store, mount or attach objects, such as cup holders or phone cradles on or next to the airbag module covers or within the airbags deployment zones.
x Only use wheel rim / tire combinations approved by Volkswagen for the respective vehicle type.
Break-in period

Damage that is caused by improper repairs or unapproved technical modifications will not be covered by any Volkswagen Limited Warranty.
WARNING
Improperly performed repairs and modifications can cause vehicle damage and malfunctions, and can impair the efficiency of driver assistance systems. This can lead to accidents and severe personal injuries.
x Have repairs and vehicle modifications done by an authorized Volkswagen dealer or an authorized Volkswagen Service Facility.
NOTICE
Improperly performed repairs and modifications can cause increased component wear and result in vehicle emissions that no longer meet applicable requirements.
Repairs and other things that can affect Advanced Airbag performance

WARNING
Leaving the optional safety belt extender attached to the safety belt buckle on the front passenger seat when the safety belt is not being used will prevent the Advanced Airbag System from working properly and can increase the risk of serious personal injury in a collision.
x Leaving the extender attached to the safety belt buckle when the front seat is occupied and the safety belt is not being used will signal to the airbag control unit that the front passenger seat is occupied and that the safety belt is being used. The electronic control unit for the airbag system will then receive incorrect information that will
– cause the safety belt pretensioner to deploy unnecessarily in collisions and
– cause the front passenger airbag to deploy later in collisions in which the front airbag would otherwise be triggered earlier to help protect an unrestrained front seat passenger.
x Always remove the safety belt extender when it is not needed and stow it safely.
x Never use the safety belt extender to secure a child restraint.
WARNING
Items stored between the safety belt buckle and the center console can cause safety belt buckle to send the wrong information to the airbag control unit and prevent the Advanced Airbag System from working properly.
x Always make sure that nothing can interfere with the safety belt buckles and that they are not obstructed.
WARNING
Improper care and servicing, and improper modification and repair work, can increase the risk of personal injury and death by preventing an airbag from deploying when needed or deploying an airbag unexpectedly:
x Never repair, adjust, or change any parts of the airbag system.
x All work on the airbag system, steering wheel, instrument panel, front seats or electrical system (including the installation of audio equipment, cellular telephones and CB radios, etc.) should be performed by authorized Volkswagen dealers or authorized Volkswagen Service Facilities. They have the necessary manuals, training, and special equipment.
x The airbag system can be activated only once. After an airbag has inflated, it must be replaced.
x Use only original equipment airbags approved by Volkswagen. Have them installed by a trained technician who has the necessary tools and diagnostic equipment to properly replace any airbag in your vehicle and assure system effectiveness in a crash.
x Never permit salvaged or recycled airbags to be installed in your vehicle.
Undeployed airbag modules and safety belt pretensioners are classified as Perchlorate Material. Special handling may apply – see http://www.dtsc.ca.gov/hazardouswaste/perchlorate. Obey all applicable legal requirements regarding handling and disposal of the vehicle or parts of its restraint system, including airbag modules and safety belts with pretensioners. Authorized Volkswagen dealers and authorized Volkswagen Service Facilities are familiar with the requirements, and we recommend that you have them perform this service for you.

Lights up Possible cause Proper response
%0# Engine control malfunction (Electronic Power Control).
Have engine checked immediately by an authorized Volkswagen dealer or authorized Volkswagen Service Facility.
D Diesel engine pre-glow before engine start-up.
B
Engine control / monitoring system malfunction (engine Malfunction Indicator Light - MIL)
Ease off the accelerator. Carefully drive to the nearest authorized Volkswagen dealer or authorized Volkswagen Service Facility. Have engine checked.