Replace VOLKSWAGEN PASSAT 2007 Service Manual

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Frequently asked questions
If you suspect a malfunction or vehicle damage, read and follow the following advice before contacting an authorized Volkswagen dealer or an authorized Volkswagen Service Facility. You may also find helpful information under “Characteristics” and “Checklist” in the index.

Description Possible causes, among others Possible remedy
Engine does not start.
Vehicle battery dead. – Perform jump-start– Charge vehicle battery
The wrong vehicle key is used. Use a valid vehicle key
Fuel level too low. Refuel
AdBlue fill level too low. Refill AdBlue
Vehicle cannot be locked or unlocked using vehicle key.
– Battery in the remote control vehicle key dead. – Too far away from vehicle (out of range). – Buttons have been pressed too many times.
– Replace the battery in the remote control vehicle key – Move closer to vehicle. – Synchronize vehicle key. – Lock or unlock vehicle manually
Unusual noises. Cold engine, braking assist systems, electronic steering column lock. Check the “Noises” entry in the index.
Odd driving behavior.
Assistance systems activated. Check the “Assistance systems” entry in the index.
DSG® Direct Shift Gearbox too hot. Stop vehicle as soon as you can do so safely
Outside mirrors move when vehicle is unlocked. Convenience settings are stored. Correct convenience settings
Front seats cannot be adjusted with power controls.
Vehicle battery dead. Charge vehicle battery
Fuse blown. Check fuse and replace if necessary
Features do not work as described in this manual.
Settings were adjusted in the Volkswagen Information System.
Check and reset to factory settings if necessary
Headlights do not light up the road as they should.
– Headlights adjusted too high.– Light bulbs burned out. – Low beams not switched on.
– Have the headlight range adjusted by an authorized Volkswagen dealer or an authorized Volkswagen Service Facility. – Change light bulbs – Switch on low beams
Electrical consumers do not work.
Vehicle battery charge too low. Charge vehicle battery
Remaining fuel level too low. Refuel
Fuse blown. Check fuse and replace if necessary
Fuel consumption higher than indicated.
– Short hauls. – “Jumpy” accelerator pedal.
– Avoid short distance driving. – Drive defensively. – Accelerate smoothly.
Electrical loads switched on. Switch off unnecessary loads.

341
Frequently asked questions
If you suspect a malfunction or vehicle damage, read and follow the following advice before contacting an authorized Volkswagen dealer or an authorized Volkswagen Service Facility. You may also find helpful information under “Characteristics” and “Checklist” in the index.

Description Possible causes, among others Possible remedy
Engine does not start.
Vehicle battery dead. – Perform jump-start– Charge vehicle battery
The wrong vehicle key is used. Use a valid vehicle key
Fuel level too low. Refuel
AdBlue fill level too low. Refill AdBlue
Vehicle cannot be locked or unlocked using vehicle key.
– Battery in the remote control vehicle key dead. – Too far away from vehicle (out of range). – Buttons have been pressed too many times.
– Replace the battery in the remote control vehicle key – Move closer to vehicle. – Synchronize vehicle key. – Lock or unlock vehicle manually
Unusual noises. Cold engine, braking assist systems, electronic steering column lock. Check the “Noises” entry in the index.
Odd driving behavior.
Assistance systems activated. Check the “Assistance systems” entry in the index.
DSG® Direct Shift Gearbox too hot. Stop vehicle as soon as you can do so safely
Outside mirrors move when vehicle is unlocked. Convenience settings are stored. Correct convenience settings
Front seats cannot be adjusted with power controls.
Vehicle battery dead. Charge vehicle battery
Fuse blown. Check fuse and replace if necessary
Features do not work as described in this manual.
Settings were adjusted in the Volkswagen Information System.
Check and reset to factory settings if necessary
Headlights do not light up the road as they should.
– Headlights adjusted too high.– Light bulbs burned out. – Low beams not switched on.
– Have the headlight range adjusted by an authorized Volkswagen dealer or an authorized Volkswagen Service Facility. – Change light bulbs – Switch on low beams
Electrical consumers do not work.
Vehicle battery charge too low. Charge vehicle battery
Remaining fuel level too low. Refuel
Fuse blown. Check fuse and replace if necessary
Fuel consumption higher than indicated.
– Short hauls. – “Jumpy” accelerator pedal.
– Avoid short distance driving. – Drive defensively. – Accelerate smoothly.
Electrical loads switched on. Switch off unnecessary loads.

363
Loosening the wheel bolts
x Push the lug wrench over the wheel bolt all the way ⇒ fig. 208.
x Holding the lug wrench at the end, loosen the wheel bolt by turning it counterclockwise about 1
complete turn (360°) ⇒ .
Loosening the anti-theft wheel bolt (where applicable)
x Take the adapter for the anti-theft wheel bolt out of the vehicle tool kit.
x Push the adapter all the way over the anti-theft wheel bolt.
x Slide the lug wrench onto the adapter until it stops.
x Holding the lug wrench at the end, loosen the wheel bolt by turning it counterclockwise about 1
complete turn (360°) ⇒ .
Important information regarding wheel bolts
The design of rims and wheel bolts is matched to the factory-installed wheels. If different wheels are installed, wheel bolts with the right length and bolt head shape must be used. The attachment of the wheels and function of the brake system depend on this.
It may not be possible to use wheel bolts from different vehicles of the same model.
Where applicable: On a wheel with a wheel cover, the anti-theft wheel bolt must be installed at points
⇒ fig. 209 (2) or (3) in relation to the position of the tire valve (1). Otherwise, the wheel cover cannot be installed.
Wheel bolt tightening torque
Correctly tightened bolts for steel and alloy wheel rims should have a torque of 103 ft-lbs. (140 Nm). After changing a wheel, have the wheel bolt tightening torque checked right away with an accurate torque wrench.
Before you check the tightening torque, replace corroded and difficult-to-turn wheel bolts and clean the threads in the wheel hub.
Never grease or oil the wheel bolts and the threads in the wheel hubs. The bolts can come loose while driving if greased or oiled, even if tightened to the required torque.
WARNING
Improperly tightened wheel bolts can come loose while driving and cause you to lose control over the vehicle, resulting in accidents and serious injuries.
x Only use wheel bolts that belong your vehicle and to the wheel being installed.
x Never use different wheel bolts.
x Wheel bolts and wheel hub threads must always be clean, easy-to-turn and free of oil and grease.
x Only use the lug wrench that is supplied with the vehicle to loosen the wheel bolts.
x Loosen the wheel bolts only about 1 turn before lifting the vehicle with the jack.
x Never grease or oil the wheel bolts and the threads in the wheel hubs. The bolts can come loose while driving if greased or oiled, even if tightened to the required torque.
x Never loosen bolted connections on wheel rims with bolted rim rings.
x If the wheel bolts are not tightened to the proper torque, the wheel can come off the vehicle when it is moving. Extremely high torque can damage the wheel bolts and/or their threads.

367
WARNING
Improper use of a compact spare wheel can cause loss of vehicle control, a crash or other accident, and serious personal injury.
x Never use a compact spare wheel if it is damaged or worn down to the wear indicators.
x Never drive faster than 50 mph (80 km/h) with a compact spare wheel. Avoid full-throttle acceleration, heavy braking, and fast cornering!
x Never drive more than 125 miles (200 km) with a compact spare wheel that is installed on the front axle (drive axle).
x Replace the compact spare with a normal wheel and tire as soon as possible. Compact spare tires are designed for brief use only.
After changing a wheel

Color Current strength in amps
Red 10
Blue 15
Yellow 20
White or clear 25
Green 30
Orange 40
Opening the fuse box in the instrument panel
x Pull the lower part of the cover in the direction of the arrow ⇒ fig. 213 and remove the cover from the bottom.
x On the inside of the cover there are plastic tweezers for removing and inserting fuses.
x To install, guide the cover from the bottom into the instrument panel and push in the direction opposite to the arrow until you can hear it latch into place.
Opening the fuse box in the engine compartment
x Open the engine hood ⇒ 
x Move the release tabs in the direction of the arrows ⇒ fig. 214 to unlock the fuse box cover.
x Remove the cover upward.
x To install push the cover onto the fuse box. The locking tabs must latch with an audible “click”.
Vehicles with battery located in the luggage compartment
There are additional fuses above the vehicle battery behind the panel on the left side of the luggage compartment. Have these fuses replaced by an authorized Volkswagen dealer or authorized Volkswagen Service Facility.
NOTICE
x To help prevent vehicle damage, be careful when removing fuse box covers and be sure to reinstall them properly.
x Open fuse boxes must be protected from dirt and moisture. Dirt and moisture in fuse boxes can cause damage to the electrical system.
The vehicle contains other fuses in addition to those mentioned in this section. Have these fuses replaced by an authorized Volkswagen dealer or an authorized Volkswagen Service Facility.

x If necessary, replace the plastic tweezers in the fuse box cover.
x Replace the cover.
NOTICE
If a fuse is replaced with a fuse with higher amperage, then damage can occur at various places in the electrical system.

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

375

NOTICE
Failure to heed warning lights or text WARNINGS can result in vehicle damage.
Information on light bulb replacement

377
⇒ 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.