Engine parts VOLKSWAGEN PASSAT 2008 User Guide

WARNING
High voltage systems in the engine compartment can cause electrical shocks or even electrocution, severe burns, other serious injuries, and even death!
x Never short-circuit the electrical system. Be especially careful when using jumper cables. The vehicle's battery could explode!
x To reduce the risk of electrical shock and personal injury while the engine is running or being started:
– Never touch ignition cables. Never touch other components of the high voltage electronic ignition system.
– Never touch the wiring of the HID – High Intensity Discharge (Xenon) headlights.
x Read and heed the important information and warnings on cleaning the engine compartment
WARNING
Moving parts in the engine compartment can cause serious personal injury on contact.
x Never reach into the area around or touch the radiator fan. Contact with the blades can cause serious personal injury. Always remember that the radiator fan is temperature-controlled and can come on suddenly even when the engine has been switched off for a while and the key has been removed from the ignition.
x If you have to perform a check or repair when the engine is running, there are more risks from the rotating parts, such as the drive belts, alternator, radiator fan, etc., and from the high-voltage ignition system. Always use extreme care.
– Always make sure that jewelry, loose clothing and long hair do not get caught in rotating engine parts. Before starting any work remove your jewelry, take off your necktie, tie back and cover your hair, and do not wear clothing that can hang down and get caught in moving engine parts.
– Always use extreme caution if the accelerator pedal has to be depressed to perform a check. The vehicle will start to move even if the parking brake is on.
x Never leave any objects in the engine compartment, for example cleaning rags and tools. Objects left behind can cause malfunctions, engine damage, and even fires.
WARNING
Operating fluids and some materials in the engine compartment can catch fire easily, causing burns and other serious personal injuries!
x Do not smoke.
x Never work next to open flames or sparks.
x Never pour or spill operating fluids or other flammable liquids on the engine. These fluids can ignite on hot engine parts and cause injuries.
x If work on the fuel system or the electrical system is necessary:
– Always disconnect the 12 Volt vehicle battery. Make sure the vehicle is unlocked when you disconnect the battery, or the alarm will go off. Never touch the electrical wiring of the ignition system.
– Never work near heaters, water heaters, or other open flames.
x Always have a functional, approved fire extinguisher nearby.

Closing the engine hood
x Pull the hood down to overcome the resistance of the gas-pressure strut ⇒ .
x Let the engine hood drop into the hood latch – do not press it afterwards!
If the hood does not close completely, open it again and close it properly.
When the hood is properly closed, you can see that it fits flush with the other body parts. The indicator
light in the instrument cluster will go out ⇒ booklet Owner's Manual Passat Model Year 2013,
Chapter Warning and indicator lights.
WARNING
If the hood is not closed properly, it could fly up and block your view while you are driving. This can lead to a crash and serious personal injuries.
x After closing the engine hood, check that the hood release lever is properly latched into the hood latch. The engine hood must be flush with the surrounding auto body parts.
x If you ever notice that the hood latch is not properly secured when the vehicle is moving, stop at once and close it.
x Never let anyone get in the way of the hood when closing it.
NOTICE
x Make sure the windshield wipers are switched off and the windshield wiper arms are resting on the windshield before you open the hood. Otherwise, the windshield wipers and the hood may be damaged.
x Always put the windshield wiper arms down against the windshield before driving the vehicle.
NOTICE
Before opening or closing the engine hood, make sure there is enough room to do so, for example when the vehicle is in a garage.

the dipstick are located, see your authorized Volkswagen dealer or authorized Volkswagen Service Facility for assistance.
5. Remove the dipstick from the guide tube and wipe the dipstick off using a clean cloth.
6. Reinsert the dipstick into the guide tube and push it all the way in. If there is an alignment tab on the engine oil dipstick, make sure it lines up with the notch in the guide tube, and that the dipstick goes all the way in.
7. Remove the dipstick again and read the oil level on the dipstick ⇒ fig. 179 as described below:
(A): Do not add any oil ⇒ . Continue with step 15.
(B): Oil may be added (about 1 pint / 0.5 liter). Continue with step 8 or step 15.
(C): You must add oil (about 1 quart / 1.0 liter). Continue with step 8.
8. After reading the oil level, reinsert the dipstick back into the guide tube and push it all the way in.
9. Remove the cap on the engine oil filler opening ⇒ fig. 180.
10. Only add engine oil that Volkswagen has approved for that engine. Add the oil gradually in small quantities (no more than 1 pint / 0.5 liter).
11. To help prevent overfilling, you must wait about 1 minute each time you add oil so that the oil can flow into the oil pan up to the marking on the dipstick.
12. Read the oil level on the dipstick again before adding another small amount, if necessary. Never
add too much oil ⇒ .
13. After adding oil, the level must at least be in the center of the ⇒ fig. 179 (B) area, but never above
(A) ⇒ .
14. After adding oil, securely install the cap on the engine oil filler opening. Otherwise, oil could leak out while the engine is running.
15. Insert the oil dipstick back in the guide tube and push it all the way in.
16. Close the hood ⇒ 
Engine oil level ranges

Required action according to the respective engine oil level:
Range (A) Do not refill oil ⇒ .
Range (B) You may add oil (about 1 pint / 0.5 l). The oil level may go into the (A) range, but not above the (A) range.
Range (C) You must add oil (about 1 quart / 1.0 l). After adding oil, make sure that the oil level is about in the middle of the (B) range.
WARNING
Engine oil can ignite when it touches hot engine parts. This can cause fires, burns, and other severe injuries.
x Never spill oil on the engine. Oil spilled on a cold engine can also cause a fire when the engine warms up.
x Always make certain that you screw the cap of the engine oil filler opening back on tightly after adding oil and that the dipstick has been pushed all the way back into the in the guide tube. This helps prevent engine oil from leaking onto the hot engine when the engine is running.

Adding engine coolant
x Always protect face, hands and arms from hot escaping coolant or steam by covering the cap with a large, thick rag.
x Carefully unscrew the cap ⇒ .
x Add only new engine coolant according to Volkswagen specifications ( Engine coolant
specifications ) ⇒ .
x The engine coolant level must be inside the marks on the side of the reservoir . Do not fill above
the top edge of the filling range! ⇒ 
x Screw the lid tightly.
x Even in an emergency, do not use any other kind of coolant additive if engine coolant meeting
Volkswagen specifications (⇒ page 296, Engine coolant specifications) is unavailable! Instead, add
distilled water only ⇒ . As soon as possible, have the correct coolant ratio restored using engine
coolant that meets Volkswagen specifications ,Engine coolant specifications.
WARNING
Hot steam and hot engine coolant can cause serious burns.
x Never open the hood if you see steam or coolant escaping from the engine compartment. Always wait until you no longer see or hear steam or coolant escaping from the engine.
x Always let the engine cool down completely before carefully opening the hood. Hot components will burn skin on contact.
x When the engine has cooled down and you are ready to open the hood:
– Firmly apply the parking brake and shift the transmission into Park (P) (automatic) or Neutral (manual only).
– Take the vehicle key out of the ignition.
– On vehicles with Keyless Access, make sure that the remote control vehicle key is out of range of the vehicle and that the vehicle cannot be started by depressing the starter
button ⇒ page 205, Starter button.
– Always keep children and others away from the engine compartment and never leave them unsupervised.
x The engine coolant system is under pressure when the engine is hot. Never unscrew the coolant expansion tank cap when the engine is hot. Hot coolant can spray out and cause severe burns and other serious injuries.
– Turn the cap slowly and very carefully in a counterclockwise direction while applying light downward pressure on the top of the cap.
– Always protect your face, hands, and arms from hot escaping coolant or steam by covering the cap with a large, thick rag.
x Never spill fluids on the engine or exhaust system when refilling. Spilling fluids onto hot parts of the engine or exhaust system can cause a fire. Under some conditions, the ethylene glycol in engine coolant can catch fire.
NOTICE
x Use distilled water only when adding coolant! All other types of water contain chemical compounds that can cause extensive corrosion damage to the engine. This can even lead to engine failure. If you have added non-distilled water, take the vehicle immediately to an authorized Volkswagen dealer or an authorized Volkswagen Service Facility to have the coolant system drained, flushed, and refilled completely with the proper coolant.

x Preparations for working in the engine compartment
x Parts, accessories, repairs and modifications
WARNING
Working on the batteries or the electrical system in your vehicle can cause serious acid burns, fires, explosions, or electrical shocks. Always read and heed the following WARNINGS and safety precautions before working on the batteries or the electrical system.
x Before working on the electrical system, always switch off the ignition and all electrical consumers and disconnect the negative (-) cable from the standard 12 Volt battery.
x When you change a light bulb, always switch off the light first.
x Always keep children away from battery acid and vehicle batteries in general.
x Always wear eye protection. Never let battery acid or lead particles come into contact with your eyes, skin, or clothing.
x Sulfuric battery acid is very corrosive. It can burn unprotected skin and cause blindness. Always wear protective gloves and eye protection. To reduce your risk of injury, never tilt the batteries, as this could spill acid through the vents and burn you.
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. If you swallow any battery acid, get medical attention immediately.
x When disconnecting the batteries from the vehicle electrical system, always disconnect the negative cable (-) first and then the positive cable (+).
x Always switch off all electrical consumers before reconnecting 12 Volt batteries. Reconnect the plus cable (+) first and then the negative cable (-). Never reverse the polarity of the connections. This could cause a fire.
x A highly explosive mixture of gases is given off when the battery is being charged.
x Do not smoke and avoid fires, sparks, and open flames when working. Never create sparks or electrostatic charges when handling cables and electrical equipment. Never short circuit the battery terminals. High-energy sparks can cause serious personal injury.
x Never use or attempt to charge a damaged or frozen battery, or a battery that was frozen but has thawed. Charging a frozen or thawed battery could cause explosions and chemical burns! Replace damaged or frozen vehicle batteries immediately. A dead battery can freeze at temperatures around +32 °F (0 °C).
x If the battery has a vent line or tube, make sure that it is properly connected to the battery.
x Always make sure that the vent line is securely attached to a vehicle battery that is located in the luggage compartment.
WARNING
California Proposition 65 Warning
x Battery posts, terminals, and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and reproductive harm. Wash your hands after handling.
NOTICE
x Do not expose the vehicle battery to direct sunlight for an extended period of time as ultraviolet rays may damage the battery housing.
x If the vehicle is left standing in the cold for a long time, protect the vehicle battery from freezing. A battery will be permanently damaged by freezing.

Undeployed battery isolator modules 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.
Emergency starting and starting the engine with a very weak vehicle battery or after the vehicle battery has been replaced may change or delete settings (including time, date, personal convenience settings and programming). Check the settings and correct as necessary once the vehicle battery has built up a sufficient charge.
Warning light

WARNING
Improperly lifting your vehicle with a workshop hoist or a floor jack can cause the vehicle to fall off and cause serious personal injury.
x Always read and heed the operating instructions from the floor jack manufacturer and legal regulations if necessary before using the floor jack to lift the vehicle.
x Never let anyone stay in the vehicle when it is being lifted or when it is off the ground.
x Always lift your vehicle only at the designated lift points shown in the illustrations
⇒ fig. 188 and ⇒ fig. 189. Not using the designated lift points can cause the vehicle to fall off the floor jack when heavy parts such as the engine or transmission are removed.
x Always make sure that the vehicle's lift points lie as flat as possible and centered on the carrier plates of the floor jack.
x Never start the engine when you have raised the vehicle on the floor jack. The engine vibrations and vehicle movements could knock the vehicle off the floor jack.
x If you must work under a vehicle raised on a floor jack, always make sure that the vehicle is safely supported on safety stands intended for that purpose that are strong enough to support the weight of the vehicle.
x Never use the floor jack as a ladder or step ladder.
x Always make sure that the weight of the vehicle is not heavier than the lifting capacity of the floor jack and safety stands being used.
NOTICE
x To help prevent serious vehicle damage, never lift the vehicle by the engine oil pan, transmission housing, or by the front or rear axles or suspension.
x To help prevent damage to the underbody or chassis, always insert a rubber pad between the hoist and the lifting points. In addition make sure the lifting arms have enough clearance.
x The lifting arms should not touch side sills or other parts of the vehicle.

Checklist
For your own safety and that of your passengers, carry out the following steps in the order listed ⇒ :
1. Park the vehicle at a safe distance from traffic and on a suitable surface ⇒ .
2. Switch on emergency flashers by pressing the  switch ⇒ fig. 190.
3. Apply the parking brake to help prevent the vehicle from moving, Braking and parking.
4. Shift the transmission into Park (P) (automatic) or Neutral (manual only), Shifting.
5. Stop the engine and remove the key from the ignition switch, Starting and stopping the engine.
6. Have all passengers exit and go to a safe location away from moving traffic, such as behind a guard rail.
7. Take all vehicle keys with you when leaving your vehicle.
8. Set up a warning triangle or other warning device in order to alert other motorists and cyclists.
9. Let the engine cool down and get expert assistance if necessary.
If the emergency flashers are on, use the turn signal lever to indicate a direction or lane change, for example when the vehicle is being towed. This temporarily interrupts the emergency flashers.
Switch on the emergency flashers when:
x Traffic suddenly slows down or stops in front of you to warn those approaching from behind.
x In any emergency situation.
x If the vehicle breaks down.
x When being towed.
Always obey traffic laws that govern the use of emergency flashers where you are driving.
If the emergency flashers are not working, a different method – as permitted by law – must be used to alert other motorists and cyclists to the breakdown.
WARNING
Disregarding the safety-related checklist may lead to accidents and serious personal injuries.
x Always review and follow the checklist. Follow accepted safety practices and use common sense.
WARNING
The vehicle exhaust system and the catalytic converter or diesel particulate filter get very hot. They can cause fires and serious personal injury.
x Never park where parts of the hot exhaust system or catalytic converter could ignite flammable materials, such as dry grass, brush, leaves, spilled fuel, etc.
The vehicle battery will be drained if the emergency flashers are on for a long time – even if the ignition is switched off.

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WARNING
Improper use of jumper cables when jump-starting a vehicle with a dead battery can cause the battery to explode, leading to serious personal injury. To help reduce the risk of battery explosion:
x All work on the batteries or the electrical system in your vehicle can cause serious acid burns, fires, or electrical shocks. Always read and heed the following WARNINGS and safety
precautions before working on the batteries or the electrical system ⇒ page 299, Vehicle battery.
x Always make sure that the battery providing starting assistance (the booster battery) has the same voltage as the dead battery (12 V) and about the same amperage capacity (see battery label).
x Never jump-start a vehicle with a thawed or frozen vehicle battery. The battery can explode. A dead battery can freeze at temperatures around +32 °F (0 °C).
x A battery that is frozen or was frozen, but has since thawed, must be replaced.
x When the vehicle battery is jump-started, it gives off hydrogen gas, which is highly explosive! Always keep fire, sparks, open flame, and smoking materials far away from vehicle batteries. Never use a cellular telephone while connecting or disconnecting jumper cables.
x Jump-start batteries only in well-ventilated areas. Batteries give off highly explosive hydrogen gas during jump-starting.
x Always route the jumper cables so that they cannot get caught in any moving parts in the engine compartment.
x Never short out the battery terminals by connecting the positive (+) and negative (-) terminals with each other.
x Never connect the negative cable from the other vehicle directly to the negative terminal of the dead battery, as this may cause the hydrogen gas given off by the dead battery to explode.
x Never attach the negative cable from the vehicle providing starting assistance to any part of the fuel system or to the brake hoses or brake lines.
x Never allow the non-insulated parts of the battery clamps to touch.
x Never allow the jumper cable attached to the positive battery terminal to contact metal parts of the vehicle.
x Always follow the instructions of the jumper cable manufacturer.
NOTICE
To help prevent extensive damage to the vehicle electrical system, read and heed the following:
x Connecting jumper cables improperly can cause a short circuit and do expensive damage to the vehicle's electrical system.
x Do not let the vehicles touch each other while the jumper cables are connected. If they do, electrical current may flow between the vehicles when the positive (+) terminals are connected, causing electrical system damage.