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Repair Group overview for Body Repairs
Repair Group
00 - Technical data
50 - Body - front
51 - Body - centre
53 - Body - rear
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Technical information should always be available to the foremen and mechanics, because their carefulandconstantadherencetotheinstructionsisessentialtoensurevehicleroad-worthinessand safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.
All rights reserved. No reproduction without prior agreement from publisher.
00 –Technical data
1Vehicle identification data
1.1Type plate and vehicle identification number
The type plate and the vehicle identification number (chassis number)arelocatednexttooneanotherontherightintheplenum chamber, immediately behind the rubber seal. It can be seen through a window in the plenum chamber cover. Vehicles for cer‐tain export countries have no type plate.
1.2Vehicle data plate
Saloon, the vehicle data plate is glued on the left of the rear cross panelintheluggagecompartment.Estate,thevehicledatasticker is located on the rear left in the spare wheel recess.
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Distancebetweenfrontmountingofsubframeandfrontmounting of assembly carrier.
Distance between middle mounting of subframe and front mount‐ing of assembly carrier.
2.3Floor group - rear Passat 1994 ➤ , Passat Variant 1994 ➤ Body Repairs - Edition 03.2003
⇒ General Information; Body Repairs, General Body Repairs ; Chapter 1 - Safety notes
1.1Removing
Note
Renewupperwheelhousinglongitudinalmembercomplete.
• Longitudinal member already cut out.
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1.1.1Cutting locations
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–Separate web plate -arrow- from suspension strut mounting and wheel housing.
–Bend web plate -arrow- towards windscreen.
–Cut wheel housing out behind suspension strut mounting.
–Remove remaining material.
1.1.2Replacement parts
♦ Front wheel housing
♦ Upper wheel housing longitudinal member
♦ Wheel housing reinforcement
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2Renewing front longitudinal member - partial renewal
WARNING
Observesafetynotes!
⇒ General Information; Body Repairs, General Body Repairs ; Chapter 1 - Safety notes
2.1Removing
2.1.1Cutting locations
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–Drill out weld points for reinforcement -1-. –Separate original joint to bulkhead.
– Locate longitudinal member parting cut approx. 20 mm before joint between front longitudinal member and rear longitudinal member.
2.1.2Right longitudinal member
–Drill out weld points for internal guide plate -2-.
–Drill out weld points for reinforcement.
–Drill out weld points for reinforcement.
–Cut out longitudinal member.
–Remove remaining material.
2.1.3Replacement parts
♦ Longitudinal member with reinforcing and weld nuts
♦ Sealing plate for longitudinal member
♦ Support
2.1.4Welding in
Preparing new part
–Transfer parting cut to new part and cut out.
–Drill 7 mm ∅ holes for SG plug weld seam.
– Secure longitudinal member to straightening bracket and butt weld, SG continuous weld seam.
–Weld in longitudinal member at wheel housing, RP spot weld seam.
–Weld in front longitudinal member, SG plug weld seam.
–Weld in longitudinal member at wheel housing, RP spot weld seam.
2.1.5Right longitudinal member
–Weld in internal guide plate again, SG plug weld seam.
–Separate original joint from inside, remove material remains.
1.1.2Replacement part
♦ Roof (with or without sunroof aperture)
1.1.3Welding in
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–Fit roof on roof frames from below and adapt to fit.
–Check gaps with windscreen and rear window in position.
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7Renewing floor panel
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WARNING
Observesafetynotes!
⇒ General Information; Body Repairs, General Body Repairs ; Chapter 1 - Safety notes
–At transition to bulkhead, staggered SG continuous weld seam.
–Weld in remaining joint, SG plug weld seam.
–Align seat cross member and hold in position.
Dimensions in mm
–Weld in seat cross member, RP spot weld seam.
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–Weld in remaining joint, SG plug weld seam.
–Adapt bearing bracket to fit and hold in position.
Dimensions in mm
–Weld in new part, SG plug weld seam.
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⇒ General Information; Body Repairs, General Body Repairs ; Chapter 1 - Safety notes
6.1Removing
6.1.1Cutting locations –Drill out weld points to reinforcement. – Make parting cut as shown. Do not damage internal reinforce‐ment -1-. Passat 1994 ➤ , Passat Variant 1994 ➤ Body Repairs - Edition 03.2003
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–Drill out original joint to inner side panel.
–Remove remaining material.
6.1.2Replacement part
♦ Longitudinal member, rear part
6.1.3Welding in
Preparing new part
–Transfer parting cut to new part and cut out.
–Drill 7 mm ∅ holes for SG plug weld seam.
– Secure longitudinal member to straightening bracket and butt weld, SG continuous weld seam.
–Longitudinal member to reinforcement -1-, SG plug weld seam.
–Spot weld rear part of longitudinal member, RP spot weld seam.
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⇒ General Information; Body Repairs, General Body Repairs ; Chapter 1 - Safety notes
9.1Removing
9.1.1Cutting locations
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–Locate parting cut according to degree of damage. –Cut out along with sealing channel depending on degree of damage.
–Remove remaining material.
9.1.2Replacement parts
♦ Side panel
♦ Sealing channel
9.1.3Welding in
Preparing new part
–Transfer parting cut to new part and cut out.
–Drill 7 mm ∅ holes for SG plug weld seam.
–Offer up side panel and check gaps with vehicle stress free.
–Weld parting cut, SG step weld seam.
–Weld in side panel, RP spot weld seam.
–Weld in remaining joint, SG plug weld seam.
–To inserts, SG tack welds.
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Passat 1994 ➤ , Passat Variant 1994 ➤
Body Repairs - Edition 03.2003
RO: 53 69 55 50
11Renewing outer wheel housing liner
WARNING
Observesafetynotes!
⇒ General Information; Body Repairs, General Body Repairs ; Chapter 1 - Safety notes
11.1Removing
• Side panel already cut out.
11.1.1Cutting locations
–Cut out wheel housing.
–Remove remaining material.
11.1.2Replacement part
♦ Outer wheel housing liner
11.1.3Welding in Preparing new part
–Drill 7 mm ∅ holes for SG plug weld seam.
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–Weld in wheel housing, SG plug weld seam.
–Spot weld remaining joint in, RP spot weld seam.
Workshop Manual
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List of Workshop Manual Repair Groups
Repair Group
01 - Self-diagnosis
27 - Starter, current supply, CCS
90 - Gauges, instruments
91 - Radio, telephone, navigation
92 - Windscreen wash/wipe system
94 - Lights, bulbs, switches - exterior
96 - Lights, bulbs, switches - interior
97 - Wiring
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Technical information should always be available to the foremen and mechanics, because their carefulandconstantadherencetotheinstructionsisessentialtoensurevehicleroad-worthinessand safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.
All rights reserved. No reproduction without prior agreement from publisher.
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• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
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01
–Self-diagnosis
1Vehicle diagnosis, testing and infor‐mation systems
♦ Vehicle diagnosis, testing and information system -VAS 5051A-
♦ Diagnosis cable -VAS 5051/6A- (5 m)
♦ Diagnosis cable -VAS 5051/5A- (3 m)
Note
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Connecting vehicle diagnosis, testing and information systemVAS 5051A- :
–Apply handbrake.
–Vehicles with an automatic gearbox, move selector lever to position “P” or “N”.
–Vehicles with manual gearbox, move gearstick to neutral po‐sition.
–Unclip cover for diagnosis connector on right of ignition lock and remove .
–With ignition switched off, connect vehicle diagnosis, testing and information system -VAS 5051A- using diagnosis leadVAS 5051/6A- to diagnostic interface -arrow- in vehicle.
–Connect vehicle diagnosis, testing and information systemVAS 5051A- ⇒ page 1 or vehicle diagnosis and service infor‐mation system -VAS 5052- ⇒ page 2 .
system - Edition 10.2004
Indicated on display:
–Press “vehicle self-diagnosis” key on the display -arrow-.
Indicated on display:
–Press “25 - Immobilizer” on screen -arrow-.
Indicated on display:
The control unit identification and the code are displayed.
♦ selected address word
♦ control unit part no.
♦ system designation (IMMO), version number
♦ coding number1)
♦ dealership number2)
1) depending on engine, gearbox and optional equipment
2) Will be automatically stored in the control unit when entering the system.
The display also shows the 17-digit chassis number (WVW....) -2- and the 14-digit identification number (VW....) -3-.
–Click on the arrow key -1- in the display.
2.1.2Overview of functions available in selfdiagnosis
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Clickon“Print”buttonondisplay-arrow-andthenon“Screen” in subsequent print menu.
The printer of vehicle diagnosis, testing and information systemVAS 5051A- then prints out either the faults displayed on the screen or “0 fault recognised”. Repair measures are required if any faults are stored. The fault print-out is needed for the repairs.
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Possible fault cause
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Fault elimination
No fault recognized! The self-diagnosis is finished If “No fault recognized” appears after com‐pleting repairs.
Data wiring defective
Implausible signal
01128
Immobilizer reading coil
Nosignalorimplausiblesignalon“W” wiring between immobilizer control unit -J362- and engine control unit or fuel shut-off valve control unit -J366- .
The baud rate (data transmission rate) of the immobilizer control unit is incorrect.
Incorrect operation:
The ignition was immediately switch‐ed back on after stopping the engine (i.e. during the shutdown phase).
Immobilizer control unit -J362- defec‐tive.
–Check wiring for open circuit or short circuit.
–Code the control unit and input the correct baud rate ⇒ page 11
– Switchignitionoff,waitatleast10 seconds, switch ignition on again and select “Read fault memory” again ⇒ page 5
–Erase the fault memory and in‐terrogate it again ⇒ page 5 , if necessary renew the immobilizer control unit -J362- .
3-pinconnectornotconnectedatcon‐trol unit or reader coil and wiring de‐fective.
Immobilizer control unit -J362- defec‐tive.
– Check connector, reader coil and wiring (visual check), if necessa‐ry renew reader coil.
–Erase the fault memory and in‐terrogate it again ⇒ page 5 , if necessary renew the immobilizer control unit -J362- .
01176
Key
Indicated on display
Signal too low
Not authorized
01177
Engine control unit
Not authorized
01179
Key programming incorrect
Possible fault cause
Reader coil or wire defective (contact resistance/loose contact).
Electronic component in ignition key (transponder) missing or does not work. Wrong transponder type in ig‐nition key.
Key fits mechanically, but adaptation routine has not been performed.
Fault elimination
– Check reader coil with wiring and connector (visual check), if nec‐essary renew reader coil.
–Renew ignition key, perform new adaptation for all ignition keys and check operation ⇒ page 14
–Re-match all ignition keys and check operation ⇒ page 14
01181
Initialisation: only 2 keys learned
Engine control unit or fuel shut-off valve control unit -J366- not adapted. W-wiring between control units is OK.
Ignition key adaptation is faulty.
Electronicsinignitionkey(transpond‐er) missing or does not work. Incorrect transponder type in ignition key.
During initial adaptation the ignition was switched on a third time with one of the ignition keys for longer than 1 second.
Onlytwoignitionkeyscanbeadapted during initial adaptation.
–Adapt engine control unit or fuel shut-off valve control unit -J366⇒ page 15
–Re-match all ignition keys and check operation ⇒ page 14
–Renew ignition key, perform new adaptation for all ignition keys and check operation ⇒ page 14
–Erase fault memory and read memory again ⇒ page 5
01202
Diagnosis lead
Short circuit
01237
Fuel shut-off valve
Defective
65535
Control unit
Defective
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Short circuit between wires of con‐nector,10-pin,chambers7and8(“W” and “K”) on immobilizer control unitJ362- .
Immobilizer control unit -J362- defec‐tive.
–Check connection and, if neces‐sary, rectify fault referring to cur‐rent flow diagram.
–Erase the fault memory and in‐terrogate it again ⇒ page 5 , if necessary renew the immobilizer control unit -J362- .
Fuel shut-off valve control unit -J366or fuel shut-off valve -N109- defec‐tive.
–Remove fuel shut-off valve con‐trol unit -J366- and disconnect electrical connection.
–Briefly apply battery voltage (ter‐minal 30) to fuel shut-off valveN109- use ( auxiliary measuring set -V.A.G 1594 C- ).
Short circuit between wires of con‐nector, 8-pin, chambers 7 and 8 (“W” and “K”).
The immobilizer control unit -J362does not recognise the correct Baud rate (data transfer speed).
Immobilizercontrolunit-J362-cannot communicate via data-bus.
–Rectify fault referring to current flow diagram
– ReplaceimmobilizercontrolunitJ362- .
– ReplaceimmobilizercontrolunitJ362- .
Passat 1994 ➤ Electrical system - Edition 10.2004
Indicated on display
Possible fault cause Fault elimination
Immobilizer control unit -J362- defec‐tive. – ReplaceimmobilizercontrolunitJ362- .
2.3Measured value blocks
2.3.1Read measured value block
–Initiating immobilizer self-diagnosis ⇒ page 3
Indicated on display:
–Press “08 - Read measured value block” on the display -arrow-.
Indicated on display:
–Press number of data block to be read on number block on display -arrow- and confirm entry with “Q” key.
Example of measured value block contents
–Press “0, 0 and 1” on number block on display and confirm input with “Q” key.
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The Passat features a second-generation immobilizer
Communications between the immobilizer control unit and the engine control unit take place on the W-wire.
The immobilizer electronics consist of:
♦ an immobilizer control unit
♦ a matched engine control unit
♦ a reader coil on the ignition lock
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♦ matchedignitionkeyswithelectroniccomponents(transpond‐er and response reader memory)
3.1 Observe additional information and per‐quisites for “online request with GeKoVW”
Prerequisites:
♦ At least one vehicle diagnosis, testing and information system -VAS 5051A- or vehicle diagnosis and service information system -VAS 5052- must be “online”.
♦ The user ID and password for GeKo-VW must be entered in the user profile of the dealership system.
Additional information:
The change affects all vehicles with an immobilizer, even older vehicles.
“GeKo-VW” means Secret and Component Protection for Volks‐wagen Vehicles.
With the introduction of “GeKo-VW” the “PIN” for the immobilizer can only be requested by “online request”.
“GeKo-VW” replaces the request for the “7-digit PIN”.
Withtheauthorisationof“GeKo-VW”theradiocodeofaVWradio can be requested via ELSA/FISH.
–Connect vehicle diagnosis, testing and information systemVAS 5051A- ⇒ page 1 or vehicle diagnosis and service infor‐mation system -VAS 5052- ⇒ page 2
–Select operating mode “Guided functions” in vehicle diagno‐sis, testing and information system -VAS 5051A- or vehicle diagnosis and service information system -VAS 5052- .
–Select following menu points one after the other according to Volkswagen brand CD:
♦ Car rest vehicles
♦ All model years
♦ All versions
♦ All engine codes
♦ Press “GoTo” key.
♦ Immobilizer l and ll
♦ Functions of immobilizer l and ll
♦ Online system test
The “online system test” is now a part of the test plan and can be initiated by pressing the “GoTo” key.
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–Connect vehicle diagnosis, testing and information systemVAS 5051A- ⇒ page 1 or vehicle diagnosis and service infor‐mation system -VAS 5052- ⇒ page 2
–Select operating mode “Guided functions” in vehicle diagno‐sis, testing and information system -VAS 5051A- or vehicle diagnosis and service information system -VAS 5052- .
–Select following menu points one after the other according to Volkswagen brand CD:
♦ Car rest vehicles
♦ All model years
♦ All versions
♦ All engine codes
♦ Press “GoTo” key.
♦ Immobilizer l and ll
♦ Functions of immobilizer l and ll
♦ Adaptation of ignition keys
The “adaption of ignition keys” is now a part of the test plan and can be initiated by pressing the “GoTo” key.
3.4Adaption after changing engine control unit
–Connect vehicle diagnosis, testing and information systemVAS 5051A- ⇒ page 1 or vehicle diagnosis and service infor‐mation system -VAS 5052- ⇒ page 2
–Select operating mode “Guided functions” in vehicle diagno‐sis, testing and information system -VAS 5051A- or vehicle diagnosis and service information system -VAS 5052- .
–Select following menu points one after the other according to Volkswagen brand CD:
♦ Car rest vehicles
♦ All model years
♦ All versions
♦ All engine codes
♦ Press “GoTo” key.
♦ Immobilizer l and ll
♦ Functions of immobilizer l and ll
♦ Adaption after changing engine control unit
The “adaption after changing engine control unit” is now a part of the test plan and can be initiated by pressing the “GoTo” key.
3.5Adapting immobilizer
–Connect vehicle diagnosis, testing and information systemVAS 5051A- ⇒ page 1 or vehicle diagnosis and service infor‐mation system -VAS 5052- ⇒ page 2 .
–Select operating mode “Guided functions” in vehicle diagno‐sis, testing and information system -VAS 5051A- or vehicle diagnosis and service information system -VAS 5052- .
–Select following menu points one after the other according to Volkswagen brand CD:
♦ Car rest vehicles
♦ All model years
♦ All versions
♦ All engine codes
♦ Press “GoTo” key.
♦ Immobilizer l and ll
♦ Functions of immobilizer l and ll
♦ Adapting immobilizer
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The “immobilizer adaption” is now a part of the test plan and can be initiated by pressing the “GoTo” key.
The battery is one of the most important electrical components in avehicle.Atroublefreebatteryhasagreatinfluenceoncustomer satisfaction. To ensure long use of the battery, the battery must be checked, serviced and maintained according to the instruc‐tions in this manual.
Apart from starting the battery has other tasks, it acts as a buffer and supplies electrical energy to the complete vehicle electrical system.
Thebatteryhasalsogonethroughatechnicalchangeandfurther developmentwillcontinue.Buttodayitisnotpossible,forreasons of physical/chemical limits, to have a completely maintenance free battery in a vehicle.
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♦ When the electrolyte level is too low the cell plates project above the surface and there is a loss of battery capacity (loss of power). If the cell plates are not covered by electrolyte (sul‐phuric acid) corrosion will occur on the plates, plate bridges and cell connectors. This corrosion ensures the battery func‐tion can no longer be guaranteed. The battery will be unusa‐ble.
– Only top-up with distilled water as this prevents electrolyte im‐purities which result in an increased self discharge.
–If the electrolyte level is too high (overfilled), e.g. above the internal electrolyte level mark (plastic web) or above the outer max.markingitisabsolutelyessentialthattheexcessiveelec‐trolytebeextractedwithacommerciallyavailablehydrometer.
–Extract the electrolyte using the hydrometer until the electro‐lyte level reaches the plastic web or the max. marking.
Check the battery voltage in a no load condition as follows:
–With battery installed and ignition switched off check voltage between terminals with test unit.
If the measuring unit displays a voltage of 12,5 V or greater the battery is OK.
The battery no load voltage must at no time drop below 12.5 V if this is the case then recharge battery immediately ⇒ page 24 Passat 1994 ➤ Electrical system - Edition 10.2004
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–Remove all battery plugs (battery cell sealing plugs).
.GAnegawsklo
Passat 1994 ➤
Electrical system - Edition 10.2004
–Immerse end of hydrometer in a cell and extract sufficient electrolyte so that float swims free in the electrolyte. This se‐quence is to be repeated until all cells have been tested.
–The greater the electrolyte density (specific density) in kg/ dm3 of the extracted electrolyte the higher the float floats free. The electrolyte density in specific density kg/dm3 can be read off the scale on the float.
Examples of unacceptable deviations in specific gravity: Specific gravity
3 per cell
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Deviations in electrolyte density in Example 1, cell 4 (1.10 kg/ dm3), as well as Example 2, cell 4 (1.14 kg/dm3 ) and cell 5 (1.18 kg/dm3 ) are not permitted. The batteries shown in the examples are no longer usable and must be disposed of.
– Thebatteryloadtestshouldbecarriedoutusingbatterytester -VAS 1979- or -VAS 5033- .
–Important: Connect the clips to battery terminal as described in the tester instruction manual. The clips must make good contact with the battery terminals.
– The load current varies and must be set on the tester accord‐ingtothebatterycapacity,thiscanbetakenfromthefollowing table ⇒ page 23
– Theminimumvoltagevaries,thevaluemustnotfallbelowthis, and can be taken from the following table.
Theloadcurrentandtheminimumvoltagevariesdependingupon the capacity of the battery and should be taken from the following table.
Table:
Passat 1994 ➤
Electrical system - Edition 10.2004
Characteristics after successfully completing battery load tests
♦ The battery voltage lowers (high current flow) caused by the high load (ohmic resistance) during this test. If a battery is in working order the battery voltage will only drop to the lowest voltage. This varies and is dependent upon the battery ca‐pacity and the low temperature test current. Low temperature testcurrentisunderstoodtomeanabatterypowerinthecold‐er periods of the year. Batteries with a high low temperature test current are specially important for vehicles with high com‐pression engines.
♦ If the battery is defective or has a lower charge state the bat‐teryvoltagedropsveryquickly“voltagecollapses”toavoltage below 9.0 V. After the test is completed, these low voltage values remain over a longer period, and the voltage increases very slowly again. A usable voltage value (no load voltage) ⇒ page 20 is no longer reached with such a battery.
♦ A battery with such faults must be noted as it no longer has the reserves of an undamaged battery.
♦ A battery with such a fault must be disposed of.
–Disconnect earth and positive cables from the battery.
– Connect battery to charging unit, positive to positive, negative to negative.
1.8.2Procedures for totally discharged bat‐teries
♦ Batteries that have not been used for a long time e.g. vehicles thathavebeenstored,self-dischargethroughconsumers(e.g. clock). If this occurs the batteries sulphate and the complete outer surface area hardens on these batteries.
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♦ If these totally discharged batteries are charged as soon as possible from this totally discharged state then the sulphation dissipates.Ifthisisnotdonetheplateshardenevenmoreand the ability to accept a charge is reduced. A reduction in the energy reserve is the result.
♦ On totally discharged batteries the electrolyte (sulphuric acid/ water mixture) is almost all water, the sulphuric acid part is heavily reduced. At minus temperatures the fluid in these bat‐teries expands and the battery housing cracks.
♦ When totally discharged batteries are charged quickly, with normalbatterychargingunits,theyacceptnochargingcurrent or through surface charging are shown as “full”. They appear to be OK. Such batteries must be charged with a low charging current as described in the following:
1.8.3Charging prerequisites for totally dis‐charged batteries
Ifatotallydischargedbattery(noloadvoltageof11.6V“Volt”and lower) is charged, the charging period must be at least 24 hours and longer. The charge current (Imax) must only be a maximum 10% of the battery capacity, e.g. for a 60 Ah battery the charge current, Imax = 6 A. The charging voltage (Umax) must only be maximum 14.4 V.
Totally discharged batteries must never be charged quickly.
❑Renewing housing only in combination with printed circuit board
10 - Contact plate for speedometer (G54)
❑Installing speedometer (G54) ⇒ page 50
11 - Bulb for illumination of digital clock
❑Black bulb holder
❑12 V/1.2 W
❑Removing and installing ⇒ page 48
12 - Warning lamps, left
❑Installation position ⇒ page 46
❑Checking LED ⇒ page 49
❑Installing ⇒ page 46
13 - Left turn signal warning lamp
❑Checking LED ⇒ page 49
❑Installing ⇒ page 46
14 - Conductor strip for illumination, dash panel insert
❑Connector for circuit board ⇒ page 48
15 - Bulb for illumination of dash panel insert
❑Blue bulb holder
❑12 V/1.2 W
16 - Speedometer (G54)
❑Installing speedometer (G54) ⇒ page 50
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2 - Conductor strip for dash panel insert illumination
3 - Connector for conductor strip
4 - Left/right turn signal warning lamps
5 - Recess for a voltage stabiliser with cooling plate which is screwed to the dash panel insert housing
6 - Warning lamps, right
7 - Warning lamps, left
8 - Digital clock, do not renew separately
Components on back of circuit board on vehicles with a digital clock
1 - Circuit board
2 - Oil pressure warning buzzer, do not renew separately
3 - Conductor strip for dash panel insert illumination
4 - Connector for conductor strip
5 - 28-pin connector for dash panel insert wiring harness
6 - Illumination for digital clock
Bulb for illumination of odometer display and multifunction indi‐cator (MFI)/digital clock
1 - Not required
2 - Bulb for illumination of odometer
3 - Bulb for illumination of MFI
isnotpermittedunlessauthorisedbyVolkswag
Figure 13 Removing and installing bulb for illumination of odom‐eter display and multifunction indicator (MFI)/digital clock –Turn bulb holder until notch -1- is vertical (unlocked) and pull out bulb.
Components on printed circuit board front on vehicles with MFI
1 - Circuit board
2 - Conductor strip for dash panel insert illumination
3 - Left/right turn signal warning lamps
4 - Warning lamps, right
5 - Odometer display, do not renew separately
6 - Warning lamps, left
7 - Multifunction indicator (MFI), do not renew separately
Components on printed circuit board back on vehicles with MFI
1 - Voltage stabiliser, do not renew separately
2 - Oil pressure warning buzzer
3 - Conductor strip for dash panel insert illumination
4 - Connector for conductor strip
5 - 28-pin connector for dash panel insert wiring harness
2.3Checking LED
The negative terminal is marked by:
1 - Phase on diode housing
2 - Larger terminal in diode housing
With some diodes the negative terminal connection is also offset.
–Simultaneously press buttons for resistance and voltage measurement -arrows- on digital multimeter -V.A.G 1315A- .
–Connect red terminal “+” to LED (+).
–Connect black terminal “-” to LED (-).
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–Slide radio level into the dash panel, until it locates in the as‐sembly frame.
1.4.3Securing aerial cable to radio unit
1 - Radio unit
2 - Cable guide
3 - Aerial cable
4 - Rubber buffer
–Secure cable guide to radio unit.
–Fit rubber buffer.
–Clip aerial cable to cable guide.
1.5Activating anti-theft coding on radio
The radio sets are supplied with a fixed code. A fixed code signi‐fies that each radio set with anti-theft coding is programmed with an individual code. This fixed code is inactive when the unit is supplied from the factory.
Thesecuritycodefortheready-to-usesetisactivatedbyentering the fixed code. The fixed code is to be activated as follows:
–Switch on radio set.
– Pressbuttons TP and TA simultaneouslyuntil“1000”appears in the digital display. Release buttons.
– Use station buttons 1 to 4 to enter the code number affixed to the radio card. Use the first button to enter the first code num‐ber, the second button to enter the second code number and so on.
–Then press buttons TP and TA simultaneously again until “SAFE” appears in the frequency display. Release buttons. Shortly afterwards a frequency will automatically appear.
If the fixed code number has been entered correctly into the radio unit, when the ignition key is removed the diode located next to the unit name will flash. If the diode flashes the radio is ready for operation and the anti-theft coding is active.
1.6Removing and installing cassette stor‐age box
–Use a suitable screwdriver to carefully lever out the cassette storage box.
–Pull cassette storage box out of centre console.
–Pull off connector.
1.6.1Removing and installing bulb for illumi‐nation
–Remove cassette storage box.
–Carefully lever cover of off back of cassette storage box
–Remove bulb for illumination
1.7Fitting location of CD changer
1.7.1Passat Variant
The CD changer is located in the compartment next to the spare wheel.
Passat 1994 ➤
Electrical system - Edition 10.2004
1.7.2Passat saloon
The CD changer is located in the luggage compartment on left side behind removable side panel trim.
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2Aerial system
2.1Roof aerial
1 - Aerial rod
2 - Aerial base
❑The roof aerial amplifier is located in the base of the aerial.
❑ Removing and installing
❑Lower rear of moulded headliner
3 - Aerial cable
❑ Fromroofaerialtolower section of right A-pillar
4 - Aerial cable
❑From lower section of rightA-pillartoradiounit
5 - M14 hexagon nut with ser‐rated washer
❑7 Nm
❑Serrated washer is at‐tached to hexagon nut with a plastic ring.
❑Apply contact grease to the inside of the roof in areaofserratedwasher.
6 - Seal
la rup op s e s , i n p a r t o r in w hole
Electrical system - Edition 10.2004
3Suppression measures
The majority of the electrical consumers in the vehicle are sup‐pressed for radio as standard.
On vehicles with radio or prepared for radio the following compo‐nents are additionally suppressed:
♦ Radiator fan -V7-
♦ Windscreen wiper motor -V-
♦ Rear window wiper motor -V12-
Additional earth connections on vehicle with radio or prepared for radio:
♦ Earth strap from left wheel housing to bonnet
♦ Earth strap from ignition transformer -N152- to engine block (petrol engines only) Passat 1994 ➤
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–Remove door trim panel ⇒ Body Repairs; Rep. Gr. 70 .
–Remove 4 screws -arrows- on loudspeaker.
–Remove loudspeaker
–Pull off connectors.
4.5.2Installing:
–Note installation marks on loudspeaker. Installation is carried out in the reverse order of removal.
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–Operate wiper motor and allow it to return to park position.
–Fit crank and align as per arrow.
1.3Adjusting wiper blade park position
A = 50 mm
B = 35 mm
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1.4Removing and installing wiper blade rubber insert
–Using a pair of pliers press together both steel strips on the enclosed side of the wiper rubber, slide sideways out of the upper clip and remove rubber complete with strips from the other clips of the wiper blades.
–Fit new rubber insert into lower clips of wiper blade.
–Guide both strips into the first groove of the rubber insert so that the recesses in the strips face the rubber and engage in the rubber lugs of the groove.
–Using pliers press both steel strips and rubber together and insert in the upper clips so that the lugs of the clips on both sides engage in the retaining slots -arrow- of the wiper blade rubber. Passat 1994 ➤ Electrical system - Edition 10.2004
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2Windscreen washer system
2.1Assembly overview - windscreen washer system
1 - Jets
❑Adjusting ⇒ page 67
2 - Hose 4 x 1
3 - Fastener
4 - Junction
isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguarantee
5 - Bushing
6 - Reservoir cap
7 - Bracket for reservoir
8 - M5 plastic nut
9 - Reservoir
❑Capacity 5 litres
10 - Windscreen washer pump
❑Connection ⇒ page 68
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2.2Adjusting washer spray jets
–Use special tool 3125.
a - -400 mm
b - 300 mm
c - -520 mm
d - -600 mm
2.3
B - Line to rear window washer system Passat 1994 ➤
Electrical system - Edition 10.2004
Connectiontowindscreenwasherpump
A - Line to windscreen washer system
3Rear window wipe/wash system
3.1Assembly overview - rear window wipe/wash system
1 - Wiper blade
❑Adjusting park position ⇒ page 69
2 - Wiper arm
3 - M8 hexagon nut
❑15 Nm
4 - Cover cap
5 - Washer
6 - Hexagon nut M16
❑7 Nm
7 - Spacer
8 - Plastic washer
9 - Rubber ring
10 - Washer
11 - Wiper motor bracket
12 - Washer
13 - M6 hexagon bolt
❑5 Nm
14 - Rubber ring
15 - Connecting pipe for wash‐er jet
16 - Washer jet
❑Adjusting ⇒ page 70
17 - Wiper motor
18 - Wiper blade rubber
❑ Removing and installing ⇒ page 66
3.2Adjusting rear window wiper park posi‐tion
a = 20 mm
Centre of wiper field Passat 1994 ➤
Electrical system - Edition 10.2004
3.3Adjusting washer spray jet
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4Headlight washer system
4.1Assembly overview - headlight washer system
1 - Reservoir cap
2 - Reservoir
❑Capacity 9 litres
3 - M5 plastic nut
4 - Hose 10 x 3
5 - Angled piece
6 - Jets
❑First remove bumper
❑Adjusting ⇒ page 71
7 - M6 nut
❑5 Nm
8 - Fastener
9 - Back-pressure valve
❑Note hose connections
10 - Seal
11 - Headlight washer system pump
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4.2Adjusting washer spray jets
–Use special tool 3019 A if necessary.
Left headlight:
a - -110 mm
b - -25 mm
c - -60 mm
d - -85 mm
Jet dimensions for the right headlight are a mirror image.
–Turn cover in direction of arrow and remove cover.
Note DonottouchbulbglasswhenfittingHalogenbulb.
– Release spring retaining clip -1- from retaining lugs and swing out.
–Pull bulb -2- out of housing. Install in reverse order of removal.
–Insert bulb so that the recess in the bulb holder aligns with guide lug of housing.
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–Remove door trim ⇒ General body repairs; Rep. Gr. 70 .
–Disconnect 2-pin connector.
–Release lower part of warning lamp from fasteners and pull off.
–Pull upper part out of door trim.
2.2Removing and installing contact switch in rear lid lock cylinder for anti-theft alarm system and central locking sys‐tem -F124-
–Remove rear lid lock and lower part of lock cylinder housing ⇒ General body repairs; Rep. Gr. 55 .
–Pull contact switch in rear lid lock cylinder for anti-theft alarm system and central locking system -F124- out of lower part of lock cylinder housing.
2.3 Removing and installing anti-theft alarm and vermin repellent system contact switch -F120-
The anti-theft alarm and vermin repellent system contact switchF120- is located on the front left of the engine compartment, near the spring strut.
2.4 Removing and installing anti-theft alarm system horn -H8-
Theanti-theftalarmsystemhornislocatedinthefrontrightwheel housing, near the suspension strut.
Removing:
–Remove front right wheel housing liner ⇒ General body re‐pairs; Rep. Gr. 66 .
–Pull 2-pin connector -2- off horn -3-.
–Remove securing bolt -1-.
Installing:
Install in reverse order of removal.
2.5 Removing and installing anti-theft alarm system control unit -J284-
Removing:
–Remove dash panel insert ⇒ page 40
–Pull connectors off control unit.
–Remove securing screws.
Installing:
Install in reverse order of removal.
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3Interior lights and switches
3.1Removing and installing light switch
– On the left above the instrument illumination regulator insert a slender object, such as a feeler gauge, max. 0.9 mm into the joint between the light switch and the fresh air vent.
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–Press catches to the right -arrow- and pull out light switch at rotary knob.
–Pull off connector.
3.1.1 Removing headlight range control regu‐lator -E102-
–Remove light switch.
–Press locating lugs on sides of headlight range control regu‐lator inwards, so that the locating lugs disengage.
– Pull headlight range control regulator to rear out of front plate of light switch.
♦ rear window regulator isolation switch -E39- with rear left win‐dow regulator switch, in driver door -E53- and rear right win‐dow regulator switch, in driver door -E55-
is the same for all components and is described for the combiwarning lamp only.
Removing:
– Insertaslenderscrewdriverorsimilarbetweenswitchhousing and dash panel and carefully release switch.
–Insert light in mounting and ensure properly located.
3.9Removing and installing sliding sunroof switch -E8-
Removing:
–Remove interior light ⇒ page 96
–Pull off connectors.
– Release fasteners on both sides of sliding sunroof switch and take switch out of interior light.
Installing:
–Insert switch in interior light and engage fasteners on sides.
–Reconnect connector and install interior light.
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3.10Removing and installing door contact switch
The procedure for removal and installation is the same for all switchesandisthereforedescribedforjustthefrontleftdoorcon‐tact switch.
Removing:
–Remove rubber boot.
–Remove screw -arrow- from door contact switch.
–Release connector.
Installing:
Install in reverse order of removal.
3.11 Removingandinstallingelectricwindow switch
Removal and installation of the
♦ front left window regulator switch -E40- , ♦ front right window regulator switch -E41- ,
♦ rear left window regulator switch, in door -E52- ,
♦ rear right window regulator switch, in door -E54is performed in the same way for all switches and is described only for the front left window regulator switch -E40- .
Removing:
–Lever off upper part of door handle.
–Pull off connector.
–Press fasteners on switch together -arrows- and release.
Installing:
–Insert switch in cut-out of door handle and engage fasteners.
–Reconnect connector and install upper part of door handle.
3.12Removing and installing mirror adjust‐ment switch -E43- with mirror adjust‐ment change-over switch -E48-
Removing:
–Lever off door handle trim.
–Pull off connector.
– Release fasteners on both sides and press switch out of door handle upper part -arrow-
Installing:
–Insert switch in cut-out of door handle and engage.
–Reconnect connector.
–Install upper part of door handle.
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