cover VOLKSWAGEN PASSAT 2007 Service Manual

WARNING
Improper replacement of burned out headlights and other light bulbs can cause serious personal injury.
x Stop! Always read and heed the WARNINGS before doing any work in the engine compartment. The engine compartment of any motor vehicle is a potentially dangerous area, and work in this area can lead to serious personal injury.
x HID – High Intensity Discharge (Xenon) headlights get power from a high voltage source that can cause severe personal injury and even death if handled improperly.
x H7 bulbs and HID – High Intensity Discharge (Xenon) headlights are under high pressure and can explode if handled improperly.
x Always let a burned out light bulb cool down before replacing it.
x Never replace a light bulb unless you are familiar with all of the necessary procedures. In particular, never remove a headlight unless you know exactly how to carry out the job and have the correct tools and light bulbs.
x If you are uncertain about what to do, have the work performed by an authorized Volkswagen dealer, an authorized Volkswagen Service Facility, or another qualified workshop. Serious personal injury may result from improperly performed work.
x We strongly recommend that you always have HID – High Intensity Discharge (Xenon) headlights and H7 bulbs replaced by a qualified technician.
x Do not touch the glass of light bulbs with your bare hands. Fingerprints left on the bulb evaporate due to the heat when the bulb is switched on and cause the reflector to “cloud.”
x There are sharp edges on and around the headlight housing in the engine compartment and the rear light housing. Wear hand protection if you replace bulbs.
NOTICE
After replacing a headlight bulb or other light bulb, always make sure that the rubber covers or plastic caps have been properly and securely reinstalled to help prevent water from getting into the electrical connections and headlight housing and damaging the electrical system.
Indicator light

Replacing headlight bulbs

Fig. 217 In the engine compartment: Covers in the left headlight assembly: A Side marker light, B Low beam headlight, C High beam headlight, D Turn signal and parking light, E Daytime running light.

Fig. 218 In the wheel housing: Removing cover.

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⇒ fig. 217 (A) (B) (C) (D) (E)
Side marker light Low beam High beam Turn signal and parking light
Daytime running lights
3.
Unscrew the fastening screw
⇒ fig. 218 (arrow) with a short screwdriver. To access the screw, turn the wheel in question inward as shown in .

Same as column (A).
4.
Remove the cover from the wheel house lining .
Same as column (A).
5. On the back of the headlight assembly, pull off the rubber cover for the bulb you are replacing.
Turn plastic
cover ⇒ fig. 217 A (E) counterclockwise and remove.
6. Left side of the vehicle: Turn plastic bulb socket counterclockwise (about 1/8 turn) to release it. Right side of the vehicle: Turn plastic bulb socket clockwise (about 1/8 turn) instead.
Turn plastic bulb socket counterclockwise (about 1/8 turn) to release it.
Press plastic tab on back of bulb socket to release it.
Same as column (A). Same as column (A).
7. Pull plastic bulb socket assembly back and out of the headlight assembly.
8. Replace the burned out light bulb with a new bulb of the same type.
9. Reinsert the bulb socket assembly into the headlight assembly.

⇒ fig. 217 (A) (B) (C) (D) (E)
Side marker light Low beam High beam Turn signal and parking light
Daytime running lights
10. Left side of the vehicle: Turn plastic bulb socket clockwise until it locks into place in the headlight assembly. Right side of the vehicle: Turn plastic bulb socket counterclockwise instead.
Turn plastic bulb socket clockwise until it locks into place in the headlight assembly.
Push bulb socket into the headlight assembly until you hear it “click” into place.
Same as column (A). Same as column (A).
11. Replace rubber cover on the back of the headlight assembly for the bulb you replaced.
Place the plastic cover A (E) in the headlight assembly housing and turn clockwise as far as it will go.
12.
Place the cover
⇒ fig. 218 in the wheel housing liner and use the screwdriver in the vehicle tool kit to tighten the fastening screw (arrow).

Same as column (A).
Please carry out each step only in the order specified:
The illustrations show the left headlight assembly from the rear. The right headlight assembly is the mirror image of the left headlight assembly.

Please carry out each step only in the order specified:
10. Attach connector plug (1) to the bulb socket assembly. The connector plug must latch with an audible “click.”
11. Slip the headlight into the mounts (small arrows) and fold rearward.
12. Screw fastening screws ⇒ fig. 219 (3) and (4) tight with the screwdriver.
13. Install cover (2) in the bumper.
14. Install cover (1) in the bumper.
Replacing taillight bulbs in the luggage compartment lid

Fig. 221 A: In the luggage compartment lid: Removing the taillight cover. B: Removing the taillight assembly.

Fig. 222 A: Taillight assembly: removing the bulb socket assembly. B: Removing the light bulbs.

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Please carry out each step only in the order specified:
3. Using the flat blade of the screwdriver in the vehicle tool kit carefully pry the cover out of
the slot ⇒ fig. 221 A (1) (arrow).
4. Pull the red locking tab B (4) in the direction of the arrow to unlock connector plug B (2).
5. Push catch B (5) to release connector plug. Then pull out connector plug B (2).
6. Remove the cover from the side of the taillight, sliding it in the direction of the arrow B. Check the original mounting position of the taillight before removing it.
7. Unscrew the fastening screws B (3) with screwdriver and carefully remove the taillight assembly from the luggage compartment lid. Pull it to the side and away from the vehicle body and place it on a clean, smooth surface.
8. Unlock the bulb socket assembly by pressing the locking tabs in direction of the arrow
⇒ fig. 222 A and remove the bulb socket assembly from the taillight assembly.
9. Replace the burned out light bulb with a new bulb of the same type B.
10. Reinsert the bulb socket assembly in the taillight assembly. The locking tabs must latch with an audible “click.”
11.
Carefully reinsert the taillight assembly into the opening in the luggage compartment lid. Hold the rear light assembly with one hand in the installation position, and with the other
hand tighten the fastening screws ⇒ fig. 221 B (3).
12. Plug connector plug B (2) into the bulb socket and push red locking tab B (4) in the direction opposite to the arrow.
13. Check the taillight assembly for proper installation and secure fit.
14. Attach the cover. The cover must latch tightly and securely into place.
15. Close the luggage compartment lid ⇒ page 57.
Different models may have different taillights, and the light bulb may be in a different location than shown in the illustrations.

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Changing light bulbs

7. Release the bulb socket assembly from the locking tabs ⇒ fig. 224 A (arrows) and remove the bulb socket assembly from the taillight assembly.
8. Replace the burned out light bulb with a new bulb of the same type B.
9. Put the bulb socket assembly in the taillight assembly. The locking tabs A must latch with an audible “click.”
Installing the taillight assembly

10. Carefully put the taillight assembly in the opening in the vehicle body.
11.
Carefully reinsert the taillight assembly into the opening in the luggage compartment lid. Hold the rear light assembly with one hand in the installation position, and with the other
hand tighten fastening screw ⇒ fig. 223 B (4).
12. Plug connector plug B (1) into the bulb socket assembly and push latch B (2) in the direction opposite to the arrow.
13. Check the taillight assembly for proper installation and secure fit.
14. Replace the small carpeted taillight access cover; and the battery trim panel, if any (see step 3 above).
15. Close the luggage compartment lid
Different models may have different taillights, and the light bulb may be in a different location than shown in the illustrations.
Replacing license plate lights

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Starting the engine
x Start the engine of the vehicle with the good battery that is providing help and let it run at idle speed.
x Turn on the ignition of the vehicle with the dead battery. If the engine starts, wait 2 to 3 minutes
until it “runs smoothly” before removing the jumper cables as described below ⇒ . If the engine does not start within about 10 seconds, turn off the ignition and wait at least 1 minute; then try again.
Before removing the jumper cables
(1) Switch off the headlights (if they are on).
(2) In the vehicle with the dead battery, switch on the heater fan and the rear window defroster. This helps to minimize voltage spikes when the cables are disconnected.
Removing the jumper cables
With the engine running, remove the jumper cables in reverse order to the way they were connected.
(1) Disconnect the black (-) cable from the vehicle with the dead battery.
(2) Disconnect the black (-) cable from the other vehicle (vehicle with the good battery).
(3) Disconnect the red (+) cable from the other vehicle (vehicle with the good battery).
(4) Disconnect the red (+) cable from the vehicle with the dead battery.
(5) Close the battery cover or snap shut the cap on the positive jump-start terminal9, as the case may be.