TallerPassat PDF

Volkswagen Passat B6 2005 - >
(B6)
Interior rearview mirror

Automatically dimming interior rearview mirror
The automatically dimming interior rearview mirror dims

progressively when the driver is "blinded" from the rear.
It consists of a mirror element and an electrical element

with two photo sensors.
The electronic element registers light incidence from the

front and rear through the photo sensors.
If the incident light from the rear is greater than that from
the front, a current flows through the electronic element to
a conductive coating.
The applied current changes the color of the electrolytes.

The electrolyte becomes darker, the greater the current is.
The incident light will be reflected to a lesser degree.
The dimming function cuts out when reverse gear is

engaged. So one can back out of a dark garage, for
example, using the rearview mirror.
Interior rearview mirror with rain sensor, removing and

installing
Removing
- In vehicles with rain sensor, switch ignition off.
- Remove left - 1 - and right cover caps -

2 - outward at the same time.
- Carefully slide rearview mirror - 3 - ,

along windshield, down off mount.
Interior rearview mirror . 2 6
- Operate connector socket locking tabs

and disconnect wiring harness from
rearview mirror.
Installing
- Installation is performed in the reverse order of removal.
Holding plate for interior rearview mirror with rain

sensor, bonding
Removal of windshield is no longer necessary, as with

previous repair procedure.
At the same time, it is possible to re-use the old, detached

mirror base.
Preparing windshield
- All adhesive and primer residue must be removed up to

ceramic coating.
- Clean adhesion surface using cleaning solution D 009

401 04 .
- Dry off period must be at least 10 minutes.
- Apply glass-/paint primer D 009 200 02 .
- Dry off period until bonding: at least 10 minutes to a

maximum of 1 hour.
Preparing detached and new mirror base
- Use a tool to remove adhesive residue (only for detached

mirror base).
- Prepare adhesive surface by wet-sanding with fine emery

paper (800-1200 grit) until water remains (does not bead
and run off) on adhesive surface.
- Then clean using cleaning solution D 009 401 04 .
Bonding mirror base
- Apply two part polyurethane adhesive D 180 KD2 A1

direct to prepared and cleaned mirror base adhesive
surface.
- Adhesive bead diameter: approx. 2.5 to 3 mm.
- Immediately after applying adhesive on mirror base,

press onto prepared windshield.
- Align mirror base on its designated position on ceramic

coating and secure using adhesive tape.
Cleaning and removing excess adhesive
- Carefully remove adhesive tape 0.5 to 1 hour after

attaching mirror base.
- Remove excess soft adhesive all around using spatula.
- Then remove any remaining excess adhesive using a

primer applicator or rag, saturated with cleaning solution.
Installation of rain sensor and mirror
- Mirror can be installed 2.5 hours after mirror base has

been attached!
Interior rearview mirror, removing and installing
Removing
- Rotate interior mirror - 1 - 90

counterclockwise - arrow - and remove
it from adhesive plate - 2 - .
Installing
Holding plate for interior rearview mirror without rain

sensor, bonding
Materials
Glass/metal glue set D 000 703 A1 (interior mirror,

standard)
Tools
1 - Window scraper (commercially available)

2 - Blade (commercially available)
- Remove retaining plate from mirror base.
- Remove PUR adhesive material from retaining plate with

wire brush.
- Grind the three spacer knobs off of adhesive surface. To

do this, lay sandpaper (360/400 grit) on flat surface.
- Keep sanded surface free of dirt and grease.
- Scrape off PUR adhesive and primer from windshield

down to ceramic layer using glass scraper.
- Clean adhesive surface with adhesive remover D 002

000 10 or cleaning solution D 009 401 04.
Warning!
Do not damage ceramic layer. Scratches always

remain visible.
- Cut nylon mesh to exact dimensions of mirror base.
Note:
Protective gloves (rubber gloves) should be worn.
- Spread thick layer of adhesive evenly on mirror base.
- Lay nylon mesh on mirror base.
- While continuing to apply adhesive with tube dab nylon

mesh.
30 seconds are available from laying the nylon mesh on

the adhesive to pressing on the windshield.
- Press mirror base (without force) onto windshield and

hold for 15 seconds.
- Use a rag to remove excess adhesive.
Note:
Mirror can be installed after 15 minutes.

Storage compartments, covers and trim . 1 50
68 - 2
Storage compartments, covers and trim

Tools
Required special tools, workshop equipment, testing and

measuring equipment, and aids
Trim removal wedge 3409
Torque wrench V.A.G 1783
Center console (without foldable armrest), removing and

installing
Note:
To provide a better overview, the seats are not

shown in the following illustration. It is not necessary
to remove the seats.
Removing
- Remove footwell trim 68-2, Footwell trim, removing

and installing
- Remove front ashtray or front compartment 68-2, Front

ashtray or front storage compartment, removing and
installing
- Remove Infotainment trim 68-2, Infotainment trim,

removing and installing
- Remove Climatronic/Climatic cover 68-2,

Climatronic/Climatic cover, removing and installing
Vehicles without Climatronic/Climatic
- Remove heater and ventilation controls
Repair Manual, Heating Air Conditioning, Repair Group

80, Heating, Ventilation
Vehicles with Climatic
- Remove heating and ventilation controls

87, Air conditioning
Vehicles with Climatronic
- Remove Climatronic operating and display unit

- Remove carpet mat - 1 - from center

console.
- Remove the two bolts - 2 - .
- Remove the two nuts - 3 - .
Note :
To remove the following screws - 4 - , the seats

must be moved accordingly.

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru

Volkswagen, Skoda, Seat, Audi
- Raise rear part of center console and

loosen console from centering tabs - 5 -
in instrument panel.
Installing
- Insert center console in the two

centering tabs - 5 - in instrument panel.
- Secure center console with two screws

- 2 - (1.5 Nm).
- Bolt in center console in rear area with

two nuts - 3 - (6 Nm).
- Secure center console in center and

side area with two bolts - 4 - (1.5 Nm).
- Lay carpet mat - 1 - in center console.
Rest of installation of center console is the reverse order of

removal.
Center console (with foldable armrest), removing and

installing
Note:
To provide a better overview, the seats are not

shown in the following illustration. It is not necessary
to remove the seats.
Removing

and installing


installing





- Remove rear trim 68-2, Rear trim, removing and

installing
- Remove the two nuts - 2 - .
Note :
In order to remove screws - 4 - , - 6 - , - 7 - and -

8 - , seats must be moved accordingly.
- Remove cover cap - 3 - and remove

screw - 4 - .
- Remove cover cap - 5 - and remove

screw - 6 - .
- Remove bolts - 7 - and - 8 - .
- Raise rear part of center console and

loosen console from centering tabs - 9 -
in instrument panel.
Installing
- Insert center console in the two

centering tabs - 9 - in instrument panel.
Note :
Check whether heating and cooling channels - 10 -

are precisely fit to the heating and cooling channels
in the center console.
- Secure center console with two screws

- 1 - (1.5 Nm).
- Bolt in center console in rear area with

two nuts - 2 - (6 Nm).
- Secure center console in rear left side

area with bolt - 4 - (6 Nm) and seal
opening with cover cap - 3 - .
- Secure center console in rear right side

area with bolt - 6 - (6 Nm) and seal
opening with cover cap - 5 - .
- Secure center console in center and

side area with two bolts - 7 - and - 8 -
(1.5 Nm).
Rest of installation of center console is the reverse order of

removal.
Footwell trim, removing and installing
Note:
Removal and installation is described for the left

side, it is the same on the right side.
To provide a better illustration, the steering wheel

parts of the gear selector and drivers seat are not
shown.
Removing
- Unclip cover - 1 - using a small

screwdriver.
- Remove bolt - 2 - (1.5 Nm).
- Remove trim from mounts in center

console - arrows A, B and C - .
- Pull trim in area of front guide - 3 - out

of mount in footwell - 4 - - arrow - .
Installing
Front ashtray or front storage compartment, removing

and installing
Note:
To provide a better illustration, the shifter knob and

boot are not shown in the illustration.
Removing
- Switch off ignition.
Vehicles with manual transmission
- Remove shifter boot upward out of mounts.
- Remove gear selector insulation - 1 -

from shifter guide rail.
Note :
Note - arrow - when installing insulation, it must

point in direction of travel.
- Remove shifter cover - 1 - upward out

of center console.
- Depending on vehicle equipment,

disconnect wiring harnesses - 2 - and -
3 - from cover.
Note :
The heating or cooling mechanism is not shown in

the illustration.
- Remove ashtray insert - 1 - or

compartment - 2 - .
- remove two screws - 3 - and - 4 - (1.5

Nm).
- Remove ashtray - 5 - or storage

compartment - 6 - from center console
and disconnect wiring harness if
necessary.
Installing
Infotainment trim, removing and installing
Note:
The adjacent components are only partially shown in

the illustration.
Removing

- Remove trim from mountings in

instrument panel.
- If present, disconnect wiring harness

from "PASSENGER AIRBAG OFF"
indicator light - 1 - .
Installing
Note:
Removal and installation of cover is described for

vehicles with Climatronic.
Removal and installation of cover for vehicles with

Climatic is the same.
The adjacent components are only partially shown in

the illustration.
Removing

- Remove trim - 1 - from mountings in

instrument panel.
Installing
Rear trim, removing and installing
Removing

Vehicles with 120 Volt socket
- Pry trim - 1 - out of mounts and

remove two bolts - 2 - (1.5 Nm).
Vehicles with a storage compartment
- Open storage compartment - 3 - and

remove two screws - 4 - (1.5 Nm).
All vehicles
- Remove rear trim from mounts in center

console.
- Depending on vehicle equipment,

disconnection wiring harnesses from rear
trim - 5 - .
Installing

Center console air duct, removing and installing
Removing
- Remove front seats 72-1, Front seat, removing and

installing

and installing

installing






installing
- Remove center console (with foldable armrest) 68-2,

installing
- Remove two screws - 1 - (1.5 Nm) and

remove front air duct - 2 - from rear air
duct - 3 - .
Installing
Center console storage compartment (without foldable

armrest), removing and installing
Removing

installing

and installing

installing





- Remove center console (without foldable armrest) 68-

2, Center console (without foldable armrest), removing and
installing
- Remove six screws - 1 - (1.5 Nm).
- Lower storage compartment - 2 -

slightly in front area.
- Slide storage compartment forward and

remove it downward from center console
- arrow - .
Installing
Center console storage compartment (without foldable

armrest), removing and installing
Removing

installing

and installing

installing






installing

installing
- Remove center console air duct 68-2, Center console

air duct, removing and installing
- Remove six screws - 1 - (1.5 Nm).
- Lower storage compartment - 2 -

slightly in front area.
- Slide storage compartment forward and

remove it downward from center console
- arrow - .
Installing
Center console extension (without foldable armrest),

Removing

installing

and installing

installing





- Remove center console (without foldable armrest) 68-

2, Center console (without foldable armrest), removing and
installing
- Remove the two sets of bolts - 1 - and

- 2- .
- Remove center console extension - 3 -

upward out of mounts in center console.
Installing
- Insert center console extension from

above into center console.
Note :
When connecting the parts, ensure all guide tabs - 1

- and centering tabs - 2 - are located in the
corresponding openings.
- Install center console extension with the

two screws - 3 - and - 4 - (1.5 Nm).
Center console extension (with foldable armrest),

Removing

installing

and installing

installing






installing

installing

- Remove center console (with foldable armrest) storage

compartment 68-2, Center console storage
compartment (without foldable armrest), removing and
installing

- 2- .
- Remove center console extension - 3 -

upward out of mounts in center console.
Installing
- Insert center console extension from above into center

console.
Note:

- Install center console extension with the two screws - 3 -

and - 4 - (1.5 Nm).
- Insert center console extension from above into center

console.
Note:

- Install center console extension with the two screws - 3 -

and - 4 - (1.5 Nm).
Center console armrest, removing and installing
Removing

installing

and installing

installing






installing
- Remove Center console (with foldable armrest) 68-2,

installing

- Remove center console storage compartment (with

armrest) 68-2, Center console storage compartment
(without foldable armrest), removing and installing
- Remove center console extension (with armrest) 68-2,

Center console extension (with foldable armrest), removing
and installing
- Remove air duct lock - 1 - from storage

compartment.

- 3 - (1.5 Nm).
- Remove wiring harness for center

console extension lights.
- Pull sides of center console extension -

5 - outward slightly and loosen armrest
frame - 4 - from extension - arrow - .
- Remove two bolts - 1 - and - 2 - (1.5

Nm) respectively.
- Remove armrest - 3 - from frame - 4 -

.
Installing
Instrument panel side covers, removing and installing
Removing
- Using trim removal wedge 3409 , pry

right side instrument panel cover - 1 -
out of locking mechanisms.
- Using trim removal wedge 3409 , pry

left side instrument panel cover - 2 - out
of locking mechanisms.
Installing
Steering column trim, removing and installing
Removing
- Remove driver-side airbag unit 69-4, Driver airbag

unit, removing and installing
- Remove steering wheel
Repair Manual, Suspension, Wheels, Brakes, Steering ,

Repair Group 48, Steering
- Loosen upper steering column trim - 1

- from mounts in lower steering column
trim - 2 - .
- Loosen upper steering column trim from

gap cover - 3 - .
- Remove the three bolts - 4 - (1.5 Nm).
- Loosen lower steering column trim - 2 -

from mounts and remove foam insert, if
necessary.
Installing
Glove compartment, removing and installing
Removing
Vehicles with CD changer.
- Remove CD changer
Repair Manual, Communication, Repair Group 91,

Communication
All vehicles
- Remove 7 bolts - 1 - , - 2 - , and - 3 -

(1.5 Nm).
- Insert a small screwdriver in the

opening - arrow - at lower end of glove
compartment and release catch.
- Loosen glove compartment from

instrument panel.
- In vehicles with glove compartment

cooling, disconnect A/C channel from
glove compartment.
- Disconnect wiring harness from lights

and contact switch.
- In vehicles with footwell lights,

disconnect wiring harness from lights.
Installing
Drivers side footwell cover, removing and installing
Removing
- Remove the two bolts - 1 - (1.5 Nm).
- Remove cover from mounts and

disconnect wiring harness (if installed)
from footwell lights.
- Press the two locking mechanisms -

arrows - and disconnect diagnostic
connector from cover.
Installing
Center instrument panel trim, removing and installing
Removing
- Pry trim - 1 - out of mountings using Trim Removal

Wedge 3409 .
Installing
Passenger-side instrument panel trim, removing and

installing
Removing
- Remove glove compartment 68-2, Glove

compartment, removing and installing
- Remove instrument panel center trim 68-2, Center

instrument panel trim, removing and installing

- Pry trim - 2 - out of mounts in area

around catches using Trim Removal
Wedge 3409 .
Installing
Instrument panel trim, removing and installing
Removing

Note :
To provide a better illustration, the steering wheel

and steering column trim are not shown in the
illustration.

Wedge 3409 .
Installing
Center compartment, removing and installing
Removing

Note :
To provide a better overview, the adjacent

components are only partially shown in the
illustration.
- Remove two screws - 1 - and - 2 -

(1.5 Nm).
- Remove compartment - 3 - from

instrument panel.
Installing
Center storage compartment unit, removing and

installing
Removing


- Remove instrument cluster trim 68-2, Instrument panel

trim, removing and installing
- Remove passenger-side instrument panel trim 68-2,

installing
Note :
To provide a better overview, the adjacent

components are only partially shown in the
illustration.
- Remove center storage compartment

unit - 2 - from instrument panel.
- Disconnect wiring harness from

warning light switch.
Installing
Cover plate carrier, removing and installing
Removing



- Remove passenger-side instrument panel trim 68-2,

installing

Wedge 3409 .
- Remove cover plate carrier - 3 - from

instrument panel.
- Disconnect wiring harness from

warning light switch.
Installing
Drivers side trim, removing and installing
Removing
- Remove left side instrument panel cover 68-2,

Instrument panel side covers, removing and installing
- Remove driver-side airbag unit 69-4, Driver airbag

unit, removing and installing
- Remove steering wheel

Repair Manual, Suspension, Wheels, Brakes, Steering ,

Repair Group 48, Steering
- Remove steering column trim 68-2, Steering column




- Remove two side screws - 1 - (1.5

Nm).
- Press rotary light switch in as far as

stop, rotate it toward right until it stands
vertically, pull it out and disconnect wiring
harness.
- Loosen trim from instrument panel.
- Disconnect wiring harnesses from

automatic headlamp range control and
parking brake switch.
- Disconnect wiring harness from ignition

lock.
Installing
Storage compartment with console in headliner,

Removing
- Remove front interior and reading lights
Repair Manual, Electrical Equipment, Repair Group 96,

Lights, Switches - Interior, Anti-theft
- Operate the two catches - arrows -

and remove storage compartment - 1 -
from console.
- Remove the two rear screws - 2 - (2

Nm).
- Remove the two front screws - 3 - (2

Nm).
- Remove console - 4 - from reinforcing

frame in headliner - 5 - .
Installing
Sun visor (standard), removing and installing
Note:
Removal and installation is described for the right-

hand side of the vehicle. Removal and installation for

the left-hand side is performed in the same manner.
Removing
- Using a small screwdriver, open cover

caps - 1 - and - 2 - .
- Remove bolts - 3 - and - 4 - (2 Nm).
- Carefully pull sun visor mount - 5 - out

of mount.
- Lightly pull on wiring harness (flat wire)

until harness connector slips out of
retaining clip in molded headliner.
- Carefully pull connector out through

opening in molded headliner, pulling out
just far enough until connector is located
closely beneath molded headliner.
Note :
Do not pull harness connector further, since the

excess length of wiring harness (flat wire) is limited
and there is a hazard it will shear off.
- Disconnect connector.
- Pull sun visor mount - 6 - out of

mount.
Installing
Note:
Slide a small foam pipe (part number 535.971.790)

over harness connector when installing sun visor.
Sun visor (double), removing and installing
Note:

Removing
- Using a small screwdriver, open cover

caps - 1 - and - 2 - .
- Remove bolts - 3 - and - 4 - (2 Nm).
- Carefully pull sun visor mount - 5 - out

of mount.
- Lightly pull on wiring harness (flat wire)

until harness connector slips out of
retaining clip in molded headliner.
- Carefully pull connector out through

opening in molded headliner, pulling out
just far enough until connector is located
closely beneath molded headliner.
Note :
Do not pull harness connector further, since the

excess length of wiring harness (flat wire) is limited
and there is a hazard it will shear off.
- Disconnect connector.
Installing
Note:
Slide a small foam pipe (part number 535.971.790)

over harness connector when installing sun visor.
Parking voucher holder
Removing
- Remove upper driver-side A-pillar trim 70-3, Upper A-

pillar trim, removing and installing
- Remove bolt - 1 - (2 Nm).

- Remove parking voucher holder - 2 -

from body.
Installing

Sill panel strips . 1 5
68 - 3
Sill panel strips

Sill panel trim, removing and installing
Note:
Removal and installation is described for the left-

the right-hand side is performed in the same
manner.
Removing
Sedan
- Remove seat bench 72-2, Seat bench (sedan),

removing and installing .
Wagon
- Fold seat bench forward.
All vehicles
- Remove side upholstery:
with rear side airbags 72-2, Side upholstery with

side airbag, removing and installing
without rear side airbags 72-2, Side upholstery

without side airbag, removing and installing
- Remove wheel housing trim 68-3, Wheel housing trim,

Note :
To provide a better illustration, the front seat is not

shown in the illustration.
- Remove sill molding - 2 - from catches

in sill in front door area.
- Loosen sill panel trim from mounts in

front area of B-pillar.
- Remove sill panel trim from catches in

door sill in rear door area.
- Thread seat belt - 3 - through slit in sill

panel trim - 2 - .
Installing
- Thread seat belt - 3 - through slit in sill

panel trim - 2 - .
- Bend sill panel trim outward in rear area

of B-pillar.
- Press sill panel trim into mounts in door

sill in rear door area.
- Place sill panel trim in corresponding

mounts in front area of B-pillar.
- Press sill panel trim into mounts in door

sill in front door area.
- Secure sill panel trim with two screws -

1 - (2 Nm).
- Check whether sill panel trim is located

in door seal moldings.
Wheel housing trim, removing and installing
Note:
Removal and installation is described for the left-

the right-hand side is performed in the same
manner.
Removing
Sedan

Wagon
- Fold seat bench forward.
All vehicles


Note :
To provide a better illustration, the rear backrest is

not shown in the illustration.
- Remove trim - 1 - in center area from

mount in body and door seal molding -
arrow A - .
- Remove trim in lower area from mount

in body - arrow B - .
- Remove trim in upper area from clip - 2

- in body - arrow C - .
Note :
To provide a better overview, the clip - 2 - is shown

removed in the illustration.
Installing
- Check whether sill panel strip is located in the door seal

molding.
Grab handles . 1 2
68 - 4
Grab handles
Roof grab handles, removing and installing
Note:

- Swivel front right grab handle away - 2

- and open both small cover caps with a
small screwdriver.
- Remove two screws - 1 - (2 Nm) and

loosen grab handle from adapter plate in
roof.
- Swivel rear right grab handle away - 4 -

and open both small cover caps with a
small screwdriver.
Grab handles . 2 2
- Remove two screws - 3 - (2 Nm) and

loosen grab handle from adapter plate in
roof.
Installing

Sun shade . 1 3
68 - 5
Sun shade
Sun shade, removing and installing
Removing
Note:
Removal of sun shade is performed when it is in a

rolled in state.
- Remove trim on C-pillars, sedan:
Vehicles without sun shade 70-3, C-pillar trim,

(sedan) (vehicles without sun shade), removing and
installing
Vehicles with sun shade 70-3, C-pillar trim

(sedan) (vehicles with sun shade), removing and
installing



- Remove rear shelf (vehicles with sun shade) 70-3,

Rear shelf (vehicles with sun shade), removing and
installing
Note :
Removal is described for the left side of the vehicle,

removal on the right side is the same.
- Remove trim - 1 - from mounts in sun

shade guide - 2 - .
- Remove sun shade guide - 2 - from

Sun shade . 2 3
mounts in body.
- Loosen sun shade guide - 2 - from

mounts in sun shade - 4 - .
- Remove two screws - 1 - (1.5 Nm) on

each holder.
- Remove sun shade - 2 - upward out of

mounts.
Sun shade . 3 3
- On vehicles with electric sun shade,

disconnect wiring harness.
Installing
Note:
Before installation, mounting elements of rear shelf

must be checked for damage and replaced if
necessary.
Screen separator wall . 1 2
68 - 6
Screen separator wall

Screen separator wall, removing and installing
Removing
- Fold backrest of rear seat bench

forward and open right rear door.
- Pull screen separator wall - 1 -

outward - arrow - out of mounts - 2 - in
right rear backrest.
Installing
Mounting components (screen separator wall), removing

and installing
Screen separator wall . 2 2
Removing
- Remove screen separator wall 68-6, Screen separator

wall, removing and installing
- Remove the two bolts - 1 - (8 Nm).
- Remove insert - 2 - and mounting

component - 3 - from right backrest.
- Remove the two bolts - 4 - (8 Nm).
- Remove insert - 5 - and mounting

component - 6 - from right backrest.
Installing

Service Training
Self-study programme 339
The Passat 2006

The Passat the unique comfort experience
S339_002
The Passat will continue its success story spanning over 30 years with the 2006 model.
It will thrill customers by offering a new level of comfort in the upper mid-size class. This is achieved by
the fact that the Passat 2006 already meets luxury class quality, safety and design standards.
It continues to offer the economy traditional in the mid-size class.
The drive concept fitted in the Passat 2006 has been redesigned to achieve these outstanding characteristics.
The engine is mounted in the classic transverse configuration.
Passat model year 2006 product characteristics:
All-encompassing comfort Uncompromising safety

Characteristic design and product aesthetics Generous amount of space and variability
Excellent quality High level of economy
Separate self-study programmes are available on the following topics:
SSP 340 The Passat 2006 - electrical system

SSP 346 The electromechanical parking brake
SSP 347 Tyre pressure monitor systems
NEW Attention
Note
The self-study programme portrays the design For current testing, adjustment and repair
and function of new developments! instructions, please refer to the customer
The contents will not be updated. service literature intended for this purpose.
2
At a glance
In brief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Heater and air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Radio and navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3
In brief
The Passat model year 2006

Where will the new Passat 2006 be built?
Like its predecessor, the new Passat will also be built

in the Emden and Zwickau plants.
VW's Emden plant
The Emden plant, in which the majority of the Passat

model vehicles will be built, was the first automobile
production plant to be certified in Europe in
September 1995. Up to December 2004, some
5.1 million Passats had been produced in the Emden
plant.
S339_098
4
Emden
Zwickau
S339_011
VW's Zwickau/Mosel plant
In Zwickau/Mosel, around 1150 Golfs and Passats are

manufactured each day, in both left and right-hand
drive versions, for all markets from Japan to North
America. In January 2003, the one millionth Passat
S339_003 rolled off the assembly line in Zwickau/Mosel.
S339_005
5
In brief
The Passat 2006

The Passat 2006 will point the way forward in many
disciplines, e.g.
- Design Dual-zone Climatronic

- Vehicle dynamics
- Drive technology
- Spatial availability
- Safety
Light assist
- Quality
Transversely mounted engine
Bluetooth premium mobile

phone pre-installation
Cornering light system

with bi-xenon
Adaptive Cruise Control
Comfortable key concept
6
High-end sound system
Boot lid easy opening
Rear lights with LED technology
S339_006
Multi-link rear suspension
Electromechanical parking brake
Tyre pressure monitor systems
230V socket
7
In brief
Technical data
Passat saloon 2006
S339_007
S339_009
S339_008
Length 4765 mm Front track 1552 mm
Width 1820 mm Rear track 1551 mm
Height 1472 mm Permissible gross vehicle weight 1950 kg
Wheelbase 2709 mm Unladen weight without driver 1391 kg
Roof load 100 kg Drag coefficient 0.281 cd
Trailed load (braked) 1300 kg Fuel tank capacity 70 litres
8
Interior dimensions
S339_010
S339_012
1 Headroom, front 973 mm
2 Headroom, rear 961 mm
3 Interior length 1797 mm
4 Luggage compartment volume 565 litres*
* Including 80 litres in the spare wheel

recess storage space
9
Body
The body structure

The new Passat's body has been optimised in terms of
the following focal points:
A-pillar
Passive safety
Lightweight design
Comfort
Pedestrian protection
This has been achieved by using high- and ultra-high-

strength steel panels and ultra-high-strength, hot-
formed steel panels.
The steel panel thicknesses have additionally been
optimised forthe relevant stresses.
The following assemblies are manufactured from

ultra-high-strength steel panels:
Front bumper cross member Cross members in the footwell area
The inner A-pillar
The seat brackets
The outer sills
The rear longitudinal members
The following assemblies are manufactured from

ultra-high-strength, hot-formed steel panels:
The front bumper cross member

The cross members in the footwell area
Inner sills
The centre tunnel
The A-pillar/roof frame area S339_152
The B-pillar
Centre tunnel
10
Centre tunnel Roof frame
B-pillar
Longitudinal member
S339_018
Ultra-high-strength, hot-formed > 1000 MPa
Steel panels < 140 MPa

Ultra-high-strength 300 - 420 MPa
Outer sills
Inner sills
S339_081
Seat brackets
Higher-strength 260 - 300 MPa High-strength 180 - 240 MPa
What are ultra-high-strength, hot-formed steel Yield strengths of the steel panels which are used:
panels?
Steel panels up to 140 MPa
These are steel panels which, as the name implies, are High-strength steel panels from 180 to 240 MPa
formed when hot at temperatures of between 900 C Higher-strength steel panels from 260 to 300 MPa
and 950 C. Ultra-high-strength steel panels from 300 to
The steel panels are provided with their high strength 420 MPa
thanks to a specific cooling process in the forming die. Ultra-high-strength, hot-formed steel panels
They are form-hardened. over 1000 MPa
The use of ultra-high-strength, hot-formed steel

panels has enabled the body weight to be lowered by 1 MPa = 1 Newton/mm2
approx. 20 kg without reducing the strength.
11
Body
The joining techniques

Thanks to the use of laser welded and soldered joints and spot welded/bonded joints, the body structure is
safeguarded in the event of a crash.
S339_019
Laser welding
Spot welding and bonding
The following joining techniques

are employed:
Laser welds Spot weld bonds
in the area of the door apertures in the area of the longitudinal member to the floor
on the front and rear roof member panel
on the lateral windscreen frame in the area of the lower sill
in the area of the front wheel housing in the area of the rear wheel housing
in the area of the lower rear window frame
on the rear cross panel
Laser soldered joints
in the roof skin

side panel/luggage compartment sealing duct
12
The flow of force in a frontal crash
In the event of a frontal crash, the forces which occur are guided into the floor panel and the roof longitudinal
members via the upper and lower longitudinal members.
Side view
frontal crash
orces from
S339_020
View from below
In the event of a lateral crash, the passenger survival

The body colours correspond to the
space is ensured by means of a triple-shell side wall.
assignment of the steel panel grades
This is supported on the underlying body structure.
from the body structure depiction.
The side wall's main component is the B-pillar,
comprised of hot-formed steel panels.
In the floor panel, the B-pillar is supported on the

ultra-high-strength steel seat bracket. In the roof, it is
supported on the high-strength steel roof cross
member.
13
Body
The seats
The front seats
4-way lumbar support
S339_021
Seat rails
Seat guidance and adjustment are carried out via

parallel seat rails. This results in finer adjustment in
comparison with the predecessor's central adjustment
rail.
Mechanical 2-way and electric 4-way lumbar support

adjustment are optionally available.
All seat variants are fitted with the familiar Active

Head Restraint System AKS.
A seat with a massage function in the backrest is

available as an additional option.
S339_022
Head restraint adjustment is carried out

via an integrated actuation mechanism.
14
The front passenger seat with
through-loading function
Front passenger seat in
With this optional seat, the seat backrest can be through-loading position
folded horizontally forwards by actuating the release
lever.
This enables the vehicle's entire passenger
compartment length to be used as transportation
space.
Release lever
S339_023
The seat occupied recognition system
The front passenger seat is fitted with a seat occupied If the sensor reports that the front passenger seat is
recognition sensor. This is located under the seat cover occupied and the belt buckle simultaneously outputs a
on the padded cushion. signal that the buckle tab is not inserted, the front
passenger is optically and acoustically requested to
don his seat belt.
Sensor for the seat occupied

recognition system
S339_024
15
Body
The rear seats

The rear seat bench is split 1/3 to 2/3.
The seat backrests can be individually folded.
S339_026
The backrest locking mechanism
The backrests are locked by means of a rotary latch

lock. Indicator
If the backrest is not locked, this is displayed via a red
indicator.
Body bow
Rotary latch lock
S339_028
16
The integrated child seats
A rear seat bench with two integrated child seats is

optionally available.
Seat cushion not raised
Lateral bolsters,
can be folded up
Seat cushion raised
Handle for raising
Footrest S339_029
Raising mechanism
The seat cushions on the outer seats can be raised. After raising the seat cushion, the lateral bolsters have
to be raised manually. On folding down, these
This serves to raise the seat for small children. automatically return to their original position.
17
Body
The door lock

The door locks are actuated by means of a Bowden cable between the door handle and the door lock.
Lock actuation
mechanism Bolt
Lever
Lever fulcrum
Bowden
cable
Door lock
S339_118
The lock cylinder
When installed, the lock cylinder is clamped into the lock actuation mechanism via a lever.
To do this, the lever is pivoted around its fulcrum by turning the bolt.
Lock cylinder not clamped Lock cylinder clamped

Lock actuation
mechanism
Bolt Bolt
Lever Lever
Aperture for
lock cylinder
Lever fulcrum
S339_133 S339_148
18
The rear window roller blind
The rear window roller blind is available as either a
mechanical or an electric version.
Button
In the mechanical variant, the roller blind is pulled
up via a handle and is locked in this position.
The electric variant is actuated using a button in the Rear window roller
centre console. blind, upper terminal
position
S339_038
The electric rear window roller blind
How it works:
The rear window roller blind guides are located in the

C-pillars. After pressing the button, a drive motor
pushes a sliding block located in each guide upwards
via two Bowden cables. The rear window roller blind
is secured to these sliding blocks. S339_031
In its upper terminal position, the drive motor is Pressing the button again causes the rear window
deactivated via an electronic force limiter. This roller blind to retract into the rear shelf. It is integrated
prevents body parts from becoming trapped between flush into the rear shelf.
the rear window roller blind and the surrounding trim
components.
Sliding block in the guide

(not visible)
Rear window roller blind,

upper terminal position
Guide slot
Guide
Guides for Bowden cables
Rear window roller blind,

lower terminal position
Drive motor S339_134
19
Occupant protection
Introduction
The Passat is equipped with the following airbags:
Two-stage driver and front passenger airbags

Head airbags
Side airbags (optional in the rear)
The outer seats are fitted with seat belts with belt
tension limiters.
Front seat belt pre-tensioners are fitted as standard.
Seat belt pre-tensioners are optionally available for
the outer rear seats.
The two-stage airbags
The new Passat is equipped with two-stage airbags on

the driver and front passenger side; these inflate to
different levels according to the accident severity.
Together with the installation position selected for the
front passenger airbag, in the upper part of the dash
panel, optimal occupant restraint is achieved with
minimal risk of injury in the event of a frontal crash
thanks to the airbags' activation.
The Passat's airbag activation system is comprised of

an airbag control unit secured in the front area of the Early crash sensor
frame tunnel; this is equipped with three internal
acceleration sensors (two sensors in the vehicle
longitudinal direction and one in the vehicle
transverse direction), an early crash sensor in the area
of the bonnet lock for supporting front crash detection
and 4 sensors for lateral crash detection.
Two sensors are designed as pressure sensors and are

located in both front doors. During a lateral collision,
these sensors measure the rise in air pressure caused
by front door deformation.
S339_120
20
Belt buckles with belt buckle interrogation are fitted
on the driver and front passenger side.
The front passenger seat is additionally equipped with
seat occupied recognition, which is carried out via a
sensor on the seat padding.
Belt buckle interrogation and seat occupied

recognition serve as a seat belt prompt system.
The front passenger airbag can be deactivated via a

key switch in the glove box.
S339_034
In the event of collisions which directly damage the In the event of lateral collisions which exclusively
front doors, this sensor concept is significantly faster affect the front of the vehicle, the vehicle lateral
and more robust than conventional measurement of acceleration measured in the airbag control unit is
the vehicle's lateral acceleration. In addition, two used for crash detection purposes.
acceleration sensors are also installed in the lower Rear crash detection is carried out using the two
area of the C-pillar to detect lateral collisions, which vehicle longitudinal acceleration sensors in the airbag
do not deform the front doors, in good time. control unit.
21
Occupant protection
The two-stage airbags

Two separate igniter circuits and charges are fitted within the two-stage airbags.
Both stages are always deployed in the event of an accident.
However, the deployment times are staggered depending on the accident severity.
In a minor accident, the time between deployment of the two stages is greater than in the event of a severe
accident.
Minor Severe
accident accident
Airbag inflation level
Airbag inflation level
2nd stage
2nd stage
Severe accident
Minor accident
1st stage
1st stage
Time Airbag inflation Time

level
S339_150
Ignition of an airbag stage
The time gap between the deployment of both stages influences the airbag's inflation level:
If the second stage is deployed later, the airbag's pressure from initial deployment has already dissipated
somewhat, and the airbag inflation level is relatively low.
If both stages are deployed shortly after each other, the airbag's pressure from initial deployment has not yet been
dissipated, and the airbag becomes harder.
22
The seat belt pre-tensioners
The outer, rear seats in the Passat 2006 are fitted with a new type of seat belt pre-tensioner.
Structure:
The belt strap is guided through the deflector in the

lower area of the C-pillar.
It is held by a cable which leads into the seat belt pre-
tensioner.
The cable is firmly anchored in the seat belt pre-
tensioner.
How it works:
If the seat belt pre-tensioner receives the deployment

signal from the airbag control unit, the pyrotechnical
propellant charge is ignited.
The force which is built up pushes the piston in the
direction of the arrow.
As a result, the cable which is secured to the piston is S339_149
carried along and now tensions the seat belt in turn.
Deflector Seat belt pre-tensioner
Deflector
Cable
Connector
Piston
S339_039
Jacket tube
Gaskets
Pyrotechnical propellant
charge
23
Engines
Engine-gearbox combinations
Petrol engine
5-speed 5-speed
manual gearbox manual gearbox
Diesel engine 0AH 0A4
1.6l/75 kW
Petrol engine
BSE
1.6l/85 kW
FSI engine
BLF
2.0l/110 kW
FSI engine
BLR
2.0l/147 kW
FSI engine (turbocharged engine)
AXX
1.9l/77 kW
TDI engine
BKC
2.0l/103 kW 4V
TDI engine
BKP
2.0l/103 kW 2V
TDI engine with diesel

particulate filter
BMP
24
6-speed 6-speed 6-speed Direct- 6-speed
manual gearbox manual gearbox manual gearbox Shift Gearbox automatic gearbox
0AJ 02S 02Q 02E 09G
25
Engines
The 1.6l/75 kW engine with

2-valve technology
The 1.6l/75 kW engine is based on the familiar 1.6 l/
75 kW engine with the engine code BGU, which is
fitted in the Golf 2004.
Special technical features
2-valve roller rocker fingers

aluminium engine block with ribbed oil pan
secondary air system
plastic variable intake manifold
pressure sensor-controlled system, previously hot
film air mass sensor (HFM)
omission of the crankcase breather, ventilation via
S339_040
the cylinder head only
omission of the exhaust gas recirculation system
Technical data Torque and output graph
Engine code BSE

Design type 4-cylinder in-line engine
Displacement 1595 cm3
Bore 81 mm
Stroke 77.4 mm
Torque (Nm)
Output (kW)
Valves per cylinder 2

Compression ratio 10.3 : 1
Max. output 75 kW at 5600 rpm
Max. torque 148 Nm at 3800 rpm
Engine management system Simos 7.2
Fuel Super unleaded RON 95
(Normal unleaded
RON 91 with slight
reduction in output)
Exhaust gas Primary catalytic converter
aftertreatment probe: linear lambda S339_041
Engine speed (rpm)
probe, secondary catalytic
converter probe:
transient probe
Exhaust emission standard EU 4
26
The 1.6l/85 kW FSI engine
This engine originates from the Golf 2004.
It differs from this only due to its switch to lambda 1
operation and super
unleaded RON 95.
Stratified charge and homogeneous lean operation

have been omitted due to the switch to lambda 1
(homogeneous operation). This leads to the
occurrence of less nitrogen oxide, and the omission
of complex trapping and regeneration of this.
This leads to the following changes: S339_042
The exhaust gas temperature sender has been The switch from super plus RON 98 to super unleaded
omitted RON 95 is achieved via ignition angle adjustment.
instead of the NOx storage reduction catalytic Operation with RON 91 is not permitted, as ignition is
converter, a three-way catalytic converter has been retarded to the control limits in this case.
installed
instead of the NOx sender, a transient
lambda probe has been installed.
Engine code BLF

Bore 76.5 mm
Stroke 86.9 mm
Torque (Nm)
Output (kW)

Compression ratio 12 : 1
Engine management system Bosch Motronic MED 9.5.10
Fuel Super unleaded with
RON 95 (super plus RON
98 leads to an increase in
torque in the medium
engine speed range)
Exhaust gas aftertreat- Primary catalytic S339_043
Engine speed (rpm)
ment converter,
main catalytic converter, Information on the fuel system can be
lambda control found in self-study programme 334
Exhaust emission standard EU 4 "The FSI engine fuel system".
27
Engines
The 2.0l/110 kW FSI engine

with 4-valve technology
The 2.0l/110 kW FSI engine dispenses with stratified
charging and the NOx sensor system.
The abbreviation FSI will be retained.
ethanol-resistant Hitachi high-pressure pump

two overhead camshafts with continuous intake
camshaft adjustment
roller rocker fingers with hydraulic supporting
element
balancer shaft gear assembly
plastic variable intake manifold with change-over
barrel S339_044
continuously variable tumble flaps
water-cooled exhaust gas recirculation
homogeneous fuel injection
Further information on this engine can be
found in SSP 322 "The 2.0l/110 kW engine
with direct petrol injection".
Engine code BLR

Bore 82.5 mm
Stroke 92.8 mm
Torque (Nm)
Output (kW)

Engine management system Bosch Motronic MED 9.5.10
Fuel Super plus unleaded
RON 98 (Super unleaded
RON 95 with slight
Exhaust gas Two primary catalytic
aftertreatment converters and one three-
way catalytic converter
with oxygen control
Engine speed (rpm)
Exhaust emission standard EU 4 S339_045
28
The 2.0l/147 kW turbo FSI
engine with 4-valve technology
A further developed turbo FSI engine is to follow on
the basis of the 2.0l/110 kW engine.
The turbo FSI engine was first launched in 2004 in the
Audi A3 Sportback and the Golf GTI.
single-branch exhaust system with underhood

primary and underfloor catalytic converter
ethanol-resistant Hitachi high-pressure pump
return-free fuel system
homogeneous fuel injection
decoupled drive sprocket in the balancer shaft
gear assembly
S339_046
elliptical toothed belt sprocket on the crankshaft
Further information on this engine can be

found in SSP 337 "The 2.0l FSI engine with
turbocharging".
Engine code AXX

Bore 82.5 mm
Stroke 92.8 mm
Torque (Nm)
Output (kW)
Max. output 147 kW at

5100-6600 rpm
Max. torque 280 Nm at
1800-4700 rpm
Engine management system Bosch Motronic MED 9.1
Camshaft adjustment 42 crank angle
Fuel Super plus unleaded
RON 98 (Super unleaded
RON 95 with slight
Exhaust gas Two three-way catalytic
aftertreatment converters with oxygen
Engine speed (rpm) S339_047
control
Exhaust emission standard EU 4
29
Engines
The diesel engines

All of the diesel engines fitted in the new Passat
comply with the EU4 exhaust emission legislation.
Optionally, vehicles with diesel engines can be Due to its underhood location, no fuel additive is
equipped with a state-of-the-art particulate filter required for soot combustion. In combination with a
system. new engine oil, the diesel particulate filters are
entirely maintenance-free.
This new system combines the oxidising catalytic
converter and the particulate filter in one component,
the catalytically coated diesel particulate filter.
Catalytically coated diesel

particulate filter
S339_146
Information on these diesel particulate filters can be found in

self-study programme 336 "The catalytically coated diesel particulate filter".
30
The 1.9l/77 kW TDI engine with
2-valve technology
This tried-and-tested 1.9l/77 kW TDI engine is also
installed in the current Golf model and in other
Volkswagen models. For installation into the Passat, it
has been modified and adapted to the new vehicle.
switchable exhaust gas recirculation cooler

crankshaft sealing flange with integrated sender
wheel for engine speed
accelerator pedal module with contact-free
accelerator pedal position senders
contact-free clutch pedal switch.
S339_048
Engine code BKC

Bore 79.5 mm
Stroke 95.5 mm
Output (kW)
Torque (Nm)

Engine management system Bosch EDC 16
Fuel Diesel, at least 51 CN
or rapeseed methyl ester
Exhaust gas Exhaust gas recirculation
aftertreatment and oxidising catalytic
converter
Exhaust emission standard EU4
31
Engines
The 2.0l/103 kW TDI engine

with 2-valve technology and
diesel particulate filter
The 2.0l/103 kW TDI engine has been developed
from the 1.9l/96 kW engine.
It was already installed in the Passat model year 2001.
In comparison with the 2.0l engine in the Passat 2001,

this engine has the following special features:
diesel particulate filter

raised turbocharger rotated by 180. Thanks to its
current installation position, the turbocharger
S339_052
offers better response behaviour and success has
been achieved in reducing the charging flow.
balancer shaft module (see page 34)
Engine code BMP

Bore 81 mm
Stroke 95.5 mm
Output (kW)
Torque (Nm)

Max. torque 320 Nm at 1750 rpm to
2500 rpm
Engine management system Bosch EDC 16
aftertreatment and diesel particulate
filter
32
The 2.0l/103 kW TDI engine
with 4-valve technology
Based on the 2.0l/103 kW 4V TDI engine fitted in the
Golf 2004 and Touran, this engine has been further
developed for the Passat 2006.
Vibrations and noise emissions have been reduced by
a balancer shaft module and new unit injectors with
piezo-electric valves.
unit injectors with piezo-electric valves

balancer shaft module (see page 34) S339_050
Engine code BKP

Bore 81 mm
Stroke 95.5 mm
Output (kW)
Torque (Nm)
Max. torque 320 Nm at 1750 rpm to

2500 rpm
Engine management system Simos PPD 1
aftertreatment and oxidising catalytic
converter
33
Engines
The unit injector with piezo-electric valve

The 2.0l/103 kW 4V TDI fitted in the Passat 2006 will be equipped with unit injectors with piezo-electric valves
for the first time. This new development offers the following advantages over the unit injector with solenoid valve:
lower noise emissions

wider range of injection pressures (130 - 2200 bar)
more flexible pilot, primary and secondary injection design
high efficiency
Further information on the unit injector with piezo-electric valve can be found in
self-study programme 352 "The unit injector with piezo-electric valve".
The balancer shaft module
Crankshaft
Silent chain
Oil pump
S339_116
Balancer shaft module
A balancer shaft module, which is located beneath the cylinder block in the oil pan, offers improved comfort. At high
speeds, it prevents the occurrence of droning noises in the interior.
The balancer shaft module contains two balancer shafts, which rotate in the opposite direction of the crankshaft and
at twice the speed. The balancer shafts are driven by the crankshaft via a silent chain.
The oil pump is secured to the balancer shaft module and is driven by one of the two balancer shafts.
34
The fuel tank
The fuel tank fitted in the Passat 2006 is comprised of two half shells manufactured from a compound of several
plastic, adhesive and barrier layers.
The two half shells are welded together after the fuel tank's internal breather system has been installed.
The fuel tank meets the following extensive requirements:
Storing the fuel

Provision of the fuel in a defined condition, with reference to pressure and delivery volume, for the relevant
mixture formation system (MPI, FSI and diesel) which is installed
Measurement of the fuel level
Compliance with environmental legislation in terms of emissions during operation and refuelling
Dissipation of critical electrostatic charges and safety functions in the event of a crash, i.e. fire resistance and
impermeability.
The fuel tanks for vehicles fitted with front-wheel drive and 4MOTION differ.
They are installed above the rear axle in both vehicle versions.
Fuel tank structure for front-wheel Fuel filler pipe

drive vehicles
Activated charcoal canister in

the rear right wheel housing
Expansion tank
Fuel pump
Heat shield
Auxiliary heater metering pump S339_107
35
Engines
The fuel delivery unit
The fuel delivery unit is installed in the fuel tank. The

following components are contained within this unit:
the fuel pump

the fuel filter (not in the diesel engine)
the fuel pressure regulator
the suction jet pumps
the potentiometer for the fuel gauge
Fuel delivery unit for vehicles with petrol engines and

front-wheel drive (MPI and FSI)
Suction jet pump
Fuel filter
Fuel pump Fuel intake pipe
Fuel pressure regulator
Float for
fuel gauge
Potentiometer for
fuel gauge
Suction jet pump
S339_108
36
The fuel delivery unit supplies the engine with the
precisely required quantity of fuel at the precisely
required pressure.
It is controlled by the engine control unit according to
the fuel requirements.
The fuel delivery units differ due to the fuel required

by the individual MPI, FSI and diesel engine systems.
Fuel delivery unit for diesel engines
Fuel pressure regulator
Suction jet pump
Fuel intake pipe

Suction unit
Potentiometer for
fuel gauge
Fuel pump
Float for
fuel gauge
S339_109
37
Engines
The fuel delivery unit with

integrated fuel pressure regulation
Fuel pump and fuel regulation initialisation depend

on the engine which is installed.
The MPI engines
The engine's fuel supply is ensured by the constant-

delivery fuel pump.
The fuel is pumped, counter to the pressure
regulator's pressure level, within the fuel delivery unit
by the fuel pump. The engine takes the quantity of
fuel which it requires and the surplus quantity flows
back into the fuel tank from the pressure regulator. S339_110
Fuel pump
The FSI engines
The fuel pump provides the engine with the qualtity of

fuel which it requires and regulates the fuel system
pressure. The engine control unit initialises the fuel
pump control unit J538 to regulate the fuel pump. The
control unit is located on the fuel delivery unit's cover.
S339_111
Fuel pump control
unit J538
The diesel engines
Thanks to their mechanical fuel pump, diesel engines

are naturally aspirated. The pre-supply pump is
located in the fuel tank. This reduces flow resistance
in the fuel lines and ensures improved re-starting
behaviour when the fuel tank has been run dry.
S339_112
Fuel pump
38
The suction jet pumps
Suction jet pump
Two suction jet pumps are located within the fuel
To the additional
delivery unit. These have the task of continuously fuel extraction point
filling the fuel pump's reservoir chamber with fuel.
This reduces the fuel pump's intake consumption, and
the fuel pump always has sufficient fuel at its
availability.
Front-wheel drive vehicles have an additional fuel

extraction point in the rear section of the fuel tank.
This additional extraction point ensures that sufficient
fuel is always available on long hill ascents.
4MOTION vehicles have an additional extraction
point in the fuel tank's antechamber.
S339_114
Suction jet pump
The fuel filter
In vehicles with petrol engines, this is located in the

upper section of the fuel delivery unit. It is designed
as a lifetime filter.
In vehicles with diesel engines, the fuel delivery unit is Fuel filter
not fitted with a fuel filter.
S339_113
The potentiometer for the fuel

gauge
The fuel level is determined by the fuel gauge float

and is transmitted to the fuel gauge potentiometer.
The determined value is displayed in the fuel gauge in
the dash panel. Float for
fuel gauge
If the sender is defective, the gauge shows that the
fuel tank is empty. Potentiometer
for fuel gauge
S339_119
39
Engines
The fuel tank for 4MOTION vehicles

The external shape of the fuel tank is determined by the available installation space, which is in turn determined by
the double wishbone rear suspension and the Haldex coupling. Its function is identical to the fuel tank fitted in
front-wheel drive vehicles.
An additional suction jet pump sucks the fuel out from the fuel tank's antechamber
(left area in direction of travel).
Fuel tank structure for 4MOTION vehicles
Fuel filler pipe
Expansion tank
Activated charcoal canister in
the rear right wheel housing
Fuel pump
Antechamber
Auxiliary heater
metering pump
Main chamber S339_115
40
Power transmission
The manual gearboxes - overview

Gearboxes which are already in use within the Group are fitted as the mechanical, manual gearboxes.
The gearboxes have merely been adapted for installation in the new Passat. As these gearboxes have already
been described more exhaustively in other self-study programmes, they will only be shown in the form of an
overview with a brief description here.
Already Technical features Also see self-

fitted study
in the: programme
No.:
Caddy Further development of the 02T gearbox 328

Shaft distance increased, final drive strengthened,
housing adapted
Without speedometer sender
5-speed manual gearbox

0AH
Golf Further development of the 02J gearbox 328

Caddy Shaft distance increased, final drive strengthened,
housing adapted

0A4
Touran Further development of the 02U gearbox 306

Extended shafts, additional gear wheel pair,
new housing cover

0AJ
Golf Further development of the 02J gearbox 306

Touran Extended shafts with additional support, additional gear
wheel pair, new, extended aluminium housing cover

02S
Golf Further development of the 02M gearbox 306

Touran Selector shaft modifications, selector forks with stops in
the housing, modified support

02Q
41
Power transmission
The 6-speed automatic

gearboxes 09G and 09M
The 6-speed automatic gearboxes set new standards The automatic gearbox with the code 09G has
in terms of dynamics and economy in the segment of already proved its worth in the Golf 2004, Touran
transversely mounted stepped automatic gearboxes. and New Beetle.
They are particularly characterised by In design and functional terms, automatic gearbox
09M corresponds to automatic gearbox 09G. It has
Low weight, merely been reinforced to cope with higher torque
High shifting comfort, transmission in the area of the couplings and brakes
Compact gearbox dimensions and and in the planetary gear sets.
High ratio between first and top gear.
Torque transmission
09G = 250 Nm
09M = 450 Nm
S339_056
The design and function of the selector lever

correspond to those in the Golf 2004. Further information on these automatic
The ignition key withdrawal lock is new. gearboxes can be found in self-study
programme No. 309
42
The 6-speed Direct-Shift
Gearbox 02E
Following its successful, initial launch in the Golf 2004 The gearbox offers the following characteristics:
and Touran, the Direct-Shift Gearbox is now also
being fitted in the Passat. Six forward gears and one reverse gear
Standard and sports gearbox programmes
The Direct-Shift Gearbox combines the advantages of Tiptronic selector level and steering wheel switches
a manual gearbox: Mechatronics
Hill-holder function
High efficiency, i.e. low fuelconsumption on a par Creep control
with a manual gearbox and Pressure oil filter and oil cooler located on the
spontaneous frictional connection with very short gearbox
shift times Maximum torque 350 Nm.
with the advantages of an automatic gearbox:
High comfort (no manual clutch actuation or

shifting)
S339_057
Thanks to its design, it meets both the requirements of active, sporty drivers and also the high comfort requirements
of rather more relaxed, forward-looking drivers who prefer automatic gearboxes.
The design and function of the selector lever

correspond to those in the Golf 2004. Further information on the Direct-Shift
The ignition key withdrawal lock is new. Gearbox can be found in self-study
programme No. 308.
43
Power transmission
The ignition key withdrawal lock

The ignition key withdrawal lock is fitted in vehicles The ignition key withdrawal lock is comprised of the
with automatic gearboxes. following components.
It prevents the ignition key from being removed if the The selector lever locked in position "P" switch F319
selector lever is not set to the "P" position. The steering column electronics control unit J527
and
If the selector lever is set to a driving position or the The ignition key withdrawal lock solenoid N376 in
"N" position, the vehicle is not secured against rolling the entry and start authorisation switch E415
away.
Entry and start authorisation

switch E415
S339_099 S339_100
Steering column electronics

control unit J527
Selector lever locked in

position "P" switch F319
S339_101
44
How it works:
Ignition switched on, selector lever in driving position or "N"
Driving position or "N"

Selector lever
S339_102
Resistor
If the selector lever is set to a driving position or "N" It supplies solenoid N376 with current and thereby
position, switch F319 is closed. activates the ignition key withdrawal lock. The ignition
key cannot be removed.
Due to the fact that switch F319 is closed, the current
circuit to control unit J527 is made. Based on the made A resistor limits the voltage to control unit J527.
current circuit, control unit J527 detects the selector
lever position.
Ignition switched on, selector lever in "P"
Parking position "P"

Selector lever
S339_103
If the selector lever is set to "P", switch F319 is open. Effects in the event of signal failure
Opening switch F319 interrupts the current circuit to If the signal from switch F319 fails or solenoid N376
control unit J527. Based on the broken current circuit, cannot be initialised, the ignition key can be removed
the control unit detects that the selector lever is in although the selector lever is not in position "P".
position "P", and the ignition key can be removed.
The flashing gear indicator notifies the driver that the
selector lever is not in position "P" and that the vehicle
is not secured against rolling away.
45
Running gear
The running gear

The running gear fitted in the Passat 2006 will be the Modern, lightweight McPherson strut front
benchmark in the mid-size class vehicle segment. This suspensionand the state-of-the-art
is achieved by consistent further development of the 4-link rear suspension therefore remain in use. The
tried-and-tested axle components in VW's modular Passat's handling behaviour, which is outstanding as
running gear system. a result of these components, is rounded off with the
electromechanical power steering system familiar
from the Golf 2004.
Safety steering column with electric

steering column lock
TRW ABS/ESP with vehicle/

trailer stabilisation
Electromechanical
power steering
Lightweight strut front suspension
Dynamic starting-off assist

Self-supporting
tyres, optional
46
However, there are also significant innovations in the The electromechanical parking brake with
Passat's running gear, e.g. AUTO HOLD function,
The new ABS/ESP system from TRW
(Thompson-Ramo-Wooldrigde) and
The tyre pressure monitor system from Hella.
Four-link rear suspension
S339_058
AUTO HOLD function,

optional
Tyre pressure monitor,

optional
Tyre pressure monitor system,

optional
More detailed information on the tyre pressure monitor systems and

the electromechanical parking brake can be found in
SSP 347 "Tyre pressure monitor systems" and in
SSP 346 "The electromechanical parking brake".
47
Running gear
The front axle

The front axle is the familiar spring strut suspension with lower wishbones.
The aluminium subframe is designed in one piece and is joined to the body with 4 bolts.
S339_123
The rear axle

The front-wheel drive Passat's rear axle is a compact four-link rear suspension in lightweight design.
S339_059
The 4MOTION rear axle
The 4MOTION rear axle is based on that fitted in the front-wheel drive vehicles and is linked to
the body via large bonded rubber bushes.
48
The steering
The Passat 2006 is fitted with electromechanical power steering. This is familiar from the Golf 2004.
Due to the high front axle loads in the Passat 2006, the characteristic power steering curves have been
adapted in the control unit.
Electric motor Control unit

S339_060
The steering column

The steering column fitted in the Passat 2006 can be adjusted vertically by 60 mm and horizontally by 50 mm.
It is equipped with an electric steering column lock. This has enabled the steering lock to be positioned in a crash-
optimised area. The position of the steering column adjustment clamping lever has also been crash-optimised and
therefore lies outside of the possible knee impact area. This has been achieved by reversing the clamping lever's
rotational direction.
Crash mechanism
(slide and tear tab) Adjustment directions
Crash element
Clamping lever for

steering column adjustment
Lower steering shaft, Steering shaft

telescopic
Single universal joint
Single universal joint with angle

to the steering box S339_124
49
Running gear
The brake system

The performance and weights of new vehicles are This encompasses:
constantly on the increase. This is due to the
continuous rise in safety and convenience equipment. A new ESP system from TRW (Thompson-Ramo-
The vehicle's brake system therefore has to be Wooldrigde) with vehicle/trailer stabilisation
adapted to these conditions. Consequently, a new Large wheel brakes
brake system has also been developed for the A brake disc wiper
Passat 2006. A tandem brake master cylinder with brake light
switch
A brake servo with "dual rate characteristics"
A hydraulic brake servo (HBV), for vehicles with
16.l/85 kW and 2.0l/110 kW FSI engines only in
combination with automatic
gearboxes
S339_061
A new brake fluid will be introduced along with the Passat 2006.
Please observe the notes in the workshop manual.
50
The anti-lock brake system
ABS/ESP TRW EBC 440
A TRW ESP system will be fitted for the first time at
Volkswagen. In addition to a hydraulic brake assist
system, this system includes an AUTO HOLD function
as an interface to the electromechanical parking
brake, plus a vehicle/trailer stabilisation system and a
brake disc wiper.
The ESP system is fitted as standard in the

Passat 2006.
S339_125
Hydraulic unit
Control unit
Hydraulic unit with brake pressure sender
To facilitate comprehension, the hydraulic unit and the

control unit are shown separately (folded open).
Hydraulic unit Control unit
S339_126
Contact for hydraulic pump

motor power supply
Brake pressure sender 1 G201 Spring contact for

brake pressure sender 1 G201
51
Running gear
The brake disc wiper

A film of water may form on the brake disc in severe By regularly applying the brake pads to the brake
rain or if the road is wet, for example; this reduces the discs from time to time at low pressure, this displaces
coefficient of friction between the brake disc and the the water film and shortens the stopping distance.
brake pads on braking. As a result, the braking effect This is carried out by cyclical initialisation of the
is temporarily changed until the water film is hydraulic pump, which builds up the low brake
dissipated by frictional heat. pressure in the brake system.
This is combated by the new function in the ESP system This process in the brake system is not perceptible to
the brake disc wiper. the driver.
Brake pressure
15 wheel revolutions 15 wheel revolutions

< 2 bar
5 min
Start of End of Time/distance

execution execution
S339_145
The vehicle/trailer stabilisation

system
A vehicle/trailer stabilisation system will be launched The trailer's pendulum movements are passed on to
in the Passat 2006 along with the TRW EBC 440 ESP the towing vehicle. This leads to yawing moments and
system. lateral forces which are detected by the yaw rate
This function is an ESP sub-system. sender and the steering angle sender and are
An unstable vehicle/trailer is stabilised by specifically processed in the ESP control unit.
braking the wheels. The vehicle/trailer's instability is combated by
building up pressure in the system and actuating
The towing vehicle's yaw rate and steering angle are individual valves in the ESP hydraulic unit.
used as input variables to achieve this.
52
The brake servo - dual rate
booster
All left-hand drive vehicles will be fitted with an
11" brake servo.
The right-hand drive vehicles will be fitted with a
7/8" tandem brake servo.
Implementation of the "dual rate characteristics"

represents a significant innovation.
S339_144
A progressive characteristic curve is achieved thanks to the brake servo's modified internal design. Even at low
pedal forces, this offers higher brake pressures than conventional brake servos. Deceleration nevertheless
commences gently when actuated in the normal manner.
Standard characteristic curve

Dual rate characteristic curve
Brake pressure
Pedal force
S339_142
53
Running gear
The brake light switch F

The brake light switch F is bolted to the brake master
cylinder. It is used to detect whether the brake pedal is
Brake master cylinder
actuated. When the brake pedal is actuated, the
brake lights are switched on.
Signal usage
The brake lights are switched on via the vehicle

electrical system control unit.
In addition, the engine control unit prevents the

vehicle from accelerating when the brake and
Brake light switch F
accelerator are actuated at the same time. To do this,
the quantity of fuel injected is reduced or the ignition S339_130
timing and throttle valve are adapted.
Brake servo
Push rod
Piston
Push rod piston
Magnetic ring
Brake light
switch F
Hall sender Brake master cylinder
Evaluation
electronics
S339_135
54
How it works:
On actuation of the brake pedal, the push rod in the

brake master cylinder pushes the piston with magnetic
ring (permanent magnet).
Brake pedal not actuated:
When the brake pedal is not actuated, the piston and

magnetic ring are at rest.
The evaluation electronics of brake light switch F
transmit a signal voltage of 0 - 2V to the engine
control unit and the vehicle electrical system control
unit. This is used to detect that the brake pedal is
not actuated.
Signal voltage to the

S339_136
engine control unit
Brake pedal actuated:
When the brake pedal is actuated, the piston is

moved over the hall sender.
When the piston's magnetic ring passes the hall
sender's switching point, the evaluation electronics
transmit a signal voltage, which is up to 2V lower than
the vehicle electrical system voltage, to the engine
control unit. This is used to detect that the brake pedal
is actuated.
Signal voltage to the

S339_137
engine control unit
55
Running gear
The brakes
Engine Front brake Rear brake

in mm in mm
312 x 25 286 x 12
75 kW
to
118 kW
S339_140 S339_138
Bolted swivel bearing
345 x 30 310 x 22
as of
132 kW
S339_141 S339_139
Bolted swivel bearing
56
The automatic levelling system
The Sachs automatic levelling system is a self-inflating
shock absorber which will be installed on the Passat's
rear suspension instead of the conventional shock
absorber.
It will be available as an optional extra at a later
point in time.
The automatic levelling system does not require any

separate components, as it makes use of relative
movements between the rear axle and the body to
maintain a specific vehicle level.
Thanks to the automatic levelling system, full spring

travel is always available for all load conditions. This
guarantees optimal ride comfort and vehicle safety.
Axle and tyre wear is additionally reduced.
S339_153
57
Running gear
The wheels and tyres
Summer tyres
Wheel
205/55 R16 91 H/V Steel 6.5J x 16 ET 42 mm

Alloy
215/55 R16 93 H/V Alloy 7J x 16 ET 45 mm
235/45 R17 74 V Alloy 7.5J x 17 ET 47 mm
Winter tyres
(suitable for snow chains)
205/55 R16 91 H/V Steel 6.5J x 16 H2 ET 42 mm

Alloy
Spare wheel
Mobility set comprised of a sealant spray bottle and compressor or
temporary spare wheel T125/70 R18 on 3.5J x 18 or
a full-size spare wheel if a variable luggage compartment floor is fitted
More detailed information on the tyre pressure monitor systems can be

found in self-study programme No. 347 "Tyre pressure monitor systems".
58
The self-supporting tyre
Self-supporting tyres will be introduced in the This is made possible by a special side wall
Passat 2006. These Bridgestone RFT tyres (Run Flat reinforcement and innovative, extremely heat-
Tyre) remain stable even in the event of full pressure resistant rubber compounds. A reinforced bead coil
loss. At a maximum speed of 80 km/h, the vehicle is ensures that the tyre is securely seated on the wheel
still able to cover a distance of up to 250 kilometres even in the event of total pressure loss.
(depending on the load and the vehicle).
One additional advantage is:
Bridgestone RFT tyres do not require special wheels
and can simply be mounted on standard wheels.
Tyre structure
Belt/strip protector layer

Tread mixture
Steel inserts
Rayon carcass layer RFT code
Side reinforcement
S339_131
Wire coil/bead coil Bead taper/bead apex
Tyre comparison
Standard tyre Self-supporting tyre
Self-supporting tyre construction

Standard tyre construction Full inflation pressure
Full inflation pressure
Deflated
Reinforced side wall

Deflated
S339_132
59
Electrical system
The fuse boxes and relay Fuse box,

positions in the vehicle electrical right of dash panel
system
The installation locations
The vehicle electrical system in the Passat 2006 has a

decentralised structure and is therefore comparable
to that in the Golf 2004. Due to the multitude of
electrical consumers, the Passat has an additional
fuse box on the right-hand side of the dash panel.
Distribution of the fuse boxes and relay positions to

different locations enables rapid and precise fault
diagnosis.
Fuse and relay box, left of

engine compartment
Strip fuses in the fuse

and relay box
60
Relay holder on the
vehicle electrical system
control unit
S339_062
Relay holder on the

vehicle electrical system
control unit
For more detailed information on the

Fuse box,
electrical system, please refer to self- left of dash panel
study programme 340 "The Passat 2006
electrical system".
61
Electrical system
The networking concept

To ensure flawless data exchange between the
individual control units, these are networked via
various data bus systems.
The data bus diagnostic interface J533 (gateway)

acts as the interface for the following data buses:
CAN powertrain data bus

CAN comfort data bus
CAN infotainment data bus
CAN instrument cluster data bus
CAN diagnostic data bus
CAN powertrain data bus
CAN comfort data bus
CAN infotainment data bus
LIN data bus
CAN sensor data bus
CAN instrument cluster data bus
CAN diagnostic data bus
CAN data busline
K line
LIN data busline
Serial data line
In addition to the CAN data bus,

certain electrical components are
networked via the LIN data bus.
62
Legend
D Ignition/starter switch
E221 Operating unit in steering wheel
G85 Steering angle sender
G273 Interior monitoring sensor
G384 Vehicle inclination sender
G397 Rain and light detector sensor
G419 ESP sensor unit
H8 Anti-theft alarm system horn
J104 Control unit for ABS
J136 Seat and steering column adjustment control
unit with memory function
J217 Automic gearbox control unit
J220 Motronic control unit
J234 Airbag control unit
J255 Climatronic control unit
J285 Control unit with display in dash panel insert
J345 Trailer detector control unit
J364 Auxiliary heater control unit
J386 Driver door control unit
J387 Front passenger door control unit
J388 Rear left door control unit
J389 Rear right door control unit
J393 Convenience system central control unit
J400 Wiper motor control unit
J412 Mobile telephone operating electronics
control unit
J428 Adaptive cruise control unit
J431 Headlight range control, control unit
J446 Parking aid control unit
J492 Four-wheel drive control unit
J500 Power steering control unit
J503 Control unit with display for radio and
navigation
S339_063
J519 Onboard supply control unit
J521 Front passenger seat adjustment with memory
control unit
J525 Digital sound package control unit
J527 Steering column electronics control unit
J533 Data bus diagnostic interface
J540 Electromechanical parking brake control unit
J587 Selector lever sensor control unit
J604 Auxiliary air heater control unit
J605 Rear lid control unit
J738 Telephone controls control unit
J764 Electronic steering column lock control unit
J788 Isolation relay for CAN powertrain bus
NOx NOx sensor
R Radio
T16 16-pin connector (diagnostic connection)
63
Electrical system
The inverter
An optional 230 V/50 Hz European socket can be
ordered for the Passat 2006.
An inverter, which is firmly connected to the socket, is
installed in the vehicle to generate the alternating
voltage. This unit is located in the rear centre console
instead of the cup holder.
S339_064
The 230 V socket is designed without an earthing

contact and can be operated at a maximum,
continuous output of 150 W. As the temporary (2 min)
peakoutput, approx. 300 W can be drawn off. Child safety lock
microswitch
Voltage can only be drawn from the socket when the

engine is running (terminal 61). Besides the engine
speed signal line, a voltage supply (terminal 30) and
a ground connection (terminal 31) link the inverter to
Status LED
the vehicle electrical system.. Galvanic separation U13 inverter with above socket*
from the alternating voltage level has been socket, 12V - 230V
implemented.
S339_065
230V socket
* Red flashing = malfunction

Green = ready to operate
No repairs may be carried out on 230V systems. If the socket or the inverter is defective,
the entire assembly must therefore be exchanged.
64
Entry and start authorisation
switch E415
The entry and start authorisation switch is part of the The emergency key serves
drive authorisation system.
to mechanically unlock the driver's door if the
The ignition key is designed without a key bit, as the vehicle cannot be opened using the radioremote
vehicle is started by pushing the key rather than control,
turningit. to deactivate the front passenger airbag,
to lock the glove box,
to lock and release the rear seat bench and
to activate the child safety lock in the rear doors.
Entry and start

authorisation switch E415
S339_066
Ignition key
S339_067
Emergency key
Lock for locking and releasing

the inserted emergency key
65
Heater and air conditioner
Climate control
Thanks to the new powertrain concept with a An identically designed air conditioner unit, which has
transversely mounted engine, the heater/ been adapted to the relevant vehicle equipment, is
air conditioner concept already implemented in used for both systems.
the Golf 2004, Touran and Caddy 2004 can be
employed. The main difference is in air distribution flap
actuation. 2C-Climatronic is fitted with an additional
Two different systems are available in the fresh air/air flow flap.
Passat 2006:
The semi-automatic heater and air conditioner

"Climatic"
The heater and air conditioner 2C-"Climatronic".
Indirect ventilation
S339_073
Air ducting
rear left
footwell vent
Air ducting Air ducting

rear centre rear right
vent footwell vent
66
Operation
Different control panel versions are available depending on the equipment fitted in the vehicle:
with or without instant heat button for the auxiliarycoolant heater

with or without potentiometer for the seat heating
with or without potentiometer for the heated windscreen
The Climatic system
In the Climatic system, the vehicle's entire interior is

comprised to form a single climatic zone.
The desired temperature is set at the left rotary switch.
The rotary switch is linked to a potentiometer, which

passes the temperature command on to the Climatic
control unit. The control unit then forwards a S339_075
calculated flap position value to the temperature flap
positioning motor.
Climatic is able to control the pre-set temperature by

monitoring the vent and interior temperature. Climatic control panel
The air distribution flaps are actuated via a flexible

ECON button Interior temperature sensor
shaft in the Climatic system.
Left seat heating Right seat heating
The air conditioner is switched on and off via the
ECON button. In ECON mode, the additional heater
is also switched off in vehicles fitted with diesel
engines.
The Climatic air conditioner unit is equipped with a

combined fresh air/recirculated air flap.
S339_074
Feedback LED
Electronic Instant heat button

rotary temperature switch auxiliary coolant heater
67
The 2C-Climatronic system
In the 2C-Climatronic system, the interior is sub-

divided into two climatic zones. This means that the
temperatures desired on the driver and front
passenger side can be set independently of each
other in the range from 16 C to 29.5 C. The climatic
zones are separated by two temperature flaps inside
the air conditioner unit.
S339_077
All air distribution and temperature control flaps are
actuated via positioning motors with an integrated
feedback potentiometer. Maintenance of the preset
interior temperature and optimal air distribution are
thereby controlled and monitored by the Climatronic
control unit.
The 2C-Climatronic system can be operated in
automatic or manual mode.
In addition to the Climatic system, 2C-Climatronic is

fitted with a fresh air flow flap, which is closed as of Climatronic control panel
100 km/h as speed increases, in order to keep the
volume of fresh air which is supplied constant. One
further function which is available is speed-
dependent blower reduction, which reduces the air
conditioner's flow noises at low speed. In cooling
mode, this is compensated by lowering the vent
temperature and by raising the ventilation
temperature in heating mode.
To prevent the windscreen from misting when the S339_076

compressor is switched off and the windscreen wipers Interior temperature sensor
are switched on, the defrost flap is automatically
opened further to conduct more air to the windscreen. Heated windscreen
68
Indirect ventilation
Manual actuation Indirect ventilation
2C-Climatronic is equipped with indirect ventilation.
An adapter positioned on the top of the air
conditioner unit enables air distribution between the
vents in the centre of the dash panel and indirect
ventilation via the electrically driven air flap for
indirect ventilation. This flap is actuated by the
indirect ventilation flap control motor V213, which is
initialised by the Climatronic control unit.
The potentiometer for the indirect ventilation flap
control motor G330 is integrated into the control S339_104
motor. This records the flap position.
Vents, centre of the dash panel
After reaching the desired temperature in

Climatronic automatic mode, the air flap in the Indirect ventilation adapter
indirect ventilation adapter is automatically To the right dash
To indirect ventilation panel vent
switched from the air duct for the vents in the
centre of the dash panel to the indirect ventilation To the left dash
air duct. panel vent
In manual mode, indirect ventilation can be
initialised by pressing the "arrow up" button on the
air conditioner control panel.
S339_122
To the vents in the centre

of the dash panel
Indirect ventilation flap
control motor V213
Air flap
Vent Air flap
on top of dash panel for indirect
ventilation Vents
in centre of
dash panel
The flow pattern
The air coming from the air conditioner unit is

forwarded in the indirect ventilation adapter
depending on the position of the air flap:
to the vents in the centre of the dash panel for

direct ventilation and
Adapter for to the vents on the top of the dash panel for
indirect ventilation indirect ventilation
From the air S339_079

conditioner unit
69
The Thermo Top V auxiliary heater

The new Passat can be fitted with the optional Thermo Top V auxiliary coolant heater.
The auxiliary heater is installed in the front right wing below the headlight.
This undertakes the following tasks:
Acts as an auxiliary heater for heating the vehicle interior and defrosting the vehicle's windows
Acts as stationary ventilation to lower the interior temperature when the vehicle is parked in the sun
Acts as an additional heater in vehicles with petrol or diesel engines (fitted as standard in diesel engines)
S339_106
Thermo Top V auxiliary Radio remote control for

coolant heater auxiliary coolant heater
For basic information on auxiliary coolant heaters, please refer to self-study

programme 280 "The Phaeton auxiliary coolant heater and additional heater
Thermo TOP C".
70
Structure
The auxiliary coolant heater control unit is integrated into the heater unit. The electrical contacts for the
combustion air blower are inserted directly into the control unit.
The auxiliary coolant heater is fitted with a second NTC temperature sensor for controlling and monitoring the
water temperature.
The combustion air enters the combustion chamber via a venturi nozzle and thereby draws in the fuel delivered
by the metering pump from the fuel line.
Water outlet
Combustion air blower Venturi nozzle

Temperature sensor
Control unit
S339_033
Heat exchanger
Electrical
connection
Fuel inlet
Combustion Exhaust gas outlet

air inlet
The venturi nozzle
The intaken air is guided through a ceramic housing,

For information on fuel pre-heating and
which is shaped as a venturi nozzle.
Thermo Top V activation, refer to self-
As a result of this, the air delivered by the combustion
study programme 318 "The Golf 2004".
air blower is accelerated to approx. 50 m/s.
The incoming fuel is therefore drawn from the fuel line
and swirled.
71
Radio and navigation
The radio systems in the

Passat 2006
Radio RCD 300
Radio RCD 300 is available as the standard radio

system for private customers.
It offers the following functions:
Two or four loudspeaker channels (20 Watts each)

RDS FM/AM European radio (AM without LW)
Indication of the stored stations with RDS names in
the display
FM 2-tuner diversity
Control via the multi-function steering wheel (MFL)
and multi-function indicator (MFI) S339_070
Integrated single-CD player
Control system for external 6-fold CD-changer
Telephone control system (hands-free)
GALA
Self-diagnosis with loudspeaker diagnosis
Transport mode
Driving school function (indication of turn signal
function and speed via the display)
Radio RCD 500
Radio RCD 500 in the Passat 2006 offers the

following functions:
Four loudspeaker channels (20 Watts each)

the display
FM 2-tuner phase diversity
Control via the MFL and MFI
Integrated single-CD player
Control system for external 6-fold CD-changer S339_071
GALA
Traffic Information Memory (TIM)
Vehicle model-specific sound adaptation
Transport mode
Optional connection of an external sound amplifier
72
Radio/navigation system MFD 2
A radio system with an integrated navigation system is

also available for the Passat 2006.
The operating sequences are similar to those of the
radio/navigation system fitted in the Touareg.
It offers the following functions, etc.:
Multi-colour display (MFD)

Dynamic guidance
Four loudspeaker channels (20 Watts each)
the display
External diversity changeover box
Control via the MFL and MFI S339_072
Control system for external 6-fold CD-changer

GALA
TIM
The cover frame has to be removed to remove or install a radio, in

order to access the threaded connection located behind it.
For further information on radios, please refer to self-study programme 342

"Radio systems".
73
Notes
74
75
339
VOLKSWAGEN AG, Wolfsburg

All rights and technical changes reserved.
000.2811.54.20 Technical status 03.2005
Volkswagen AG
Service Training VK-21
Brieffach 1995
D-38436 Wolfsburg
This paper has been manufactured from cellulose bleached without the use of chlorine.
Service Training
Self-study Programme 340
The Passat 2006

Electrical System
Design and Function

The Passat 2006 features further innovations in One example is the entry and start authorisation
the area of vehicle electrics and electronics. switch. For the first time, you do not have to turn
the ignition key to start the engine.
The developers have paid particular attention to
comfort in this car. This self-study programme should help you get to
know the electrical system in the Passat 2006
and become familiar with the new features.
S340_072
NEW Important
Note
The self-study programme shows the design and function For current testing, adjustment and repair instructions,
of new developments. refer to the relevant
The contents will not be updated. service literature.
2
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Data Bus Systems

Control Units for Powertrain CAN Data Bus . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Control Units for Convenience CAN Data Bus . . . . . . . . . . . . . . . . . . . . . . . 10
Control Units for Infotainment CAN Data Bus
Combi and Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Sub-bus Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Onboard Power Supply

Electronics Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Relay Carriers and Fuse Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Onboard Power Supply Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Exterior lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Data Bus Diagnostic Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Control Unit with Display in Dash Panel Insert . . . . . . . . . . . . . . . . . . . . . . . 34
Convenience System Central Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Immobilizer IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Start-Stop System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Electronic Steering Column Lock Control Unit . . . . . . . . . . . . . . . . . . . . . . . 46
Convenience and Safety Electronics

Corning Light System (Advanced Frontlighting System) . . . . . . . . . . . . . . . . 48
Customisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Parking Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Test Yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3
Introduction
Fuse Boxes and Relay Locations in the Onboard Power Supply

Locations
The Passat 2006 onboard power supply is
decentralised and is therefore similar to the
Golf 2004 system. The Passat also has a fuse box
on the right-hand side of the dash panel due to
the large number of electrical consumers.
The distribution of the fuse boxes and relays

among different locations allows fast and precise
fault diagnosis. Fuse box,
in right-hand side of
dash panel
Electronics box,
on left of engine compartment
Back-up fuse box,

on left of engine compartment
4
Relay carrier,
on left under dash panel,
above onboard power supply
control unit
Relay carrier on onboard power

supply control unit,
on left under dash panel
S340_001
Fuse box,
on left in dash panel
5
Introduction
Networking Concept
Overview of networked control units
The data bus diagnostic interface J533 forms the
interface for communication among the
J428
following data bus systems:
T16
- Powertrain CAN data bus J788 J623 J583

- Convenience CAN data bus
- Infotainment CAN data bus
- Combi CAN data bus
- Diagnostics CAN data bus J745 J667
The following data bus systems are connected

downstream of a CAN data bus system as a J668
sub-bus system:
- LIN data bus J285

J533
- CAN data bus, electromechanical
parking brake J503 / R
- Sensor CAN data bus J345 J521
- Cornering lights CAN data bus
- Serial data bus
J412
J519
Powertrain J525
CAN data bus
Convenience
CAN data bus J255 J136
Infotainment J364
CAN data bus
Cornering lights
CAN data bus
CAN data bus J738
J386 J388
LIN data bus
Sensor
CAN data bus J387 J389
Combi CAN
data bus
Diagnostics
CAN data bus
CAN data bus
cable
Communications line
LIN data bus

cable
Serial data bus
cable
S340_003
6
E221 Operating unit in steering wheel
E415 Entry and start authorisation switch
G85 Steering angle sender
G397 Rain and light detector sensor
G419 J540 G419 ESP sensor unit
H12 Alarm horn
J104 ABS control unit
J217 J136 Seat and steering column adjustment
J492 J104
J743 control unit with memory
J217 Automatic gearbox control unit
J234 Airbag control unit
J255 Climatronic control unit
J587 J500 J285 Control unit with display in dash panel insert
J364 Auxiliary heater control unit
J234 J387 Front passenger door control unit
G85 J388 Rear left door control unit
J389 Rear right door control unit
E221
E415
J527
J412 Mobile telephone operating electronics control unit
J428 Adaptive cruise control unit
J446 J605 J446 Parking aid control unit
J492 Four-wheel drive control unit
J500 Power steering control unit
J503 Control unit with display for radio and
navigation
J400 J519 Onboard power supply control unit
J521 Front passenger seat position with memory
G397
control unit
J525 Digital sound package control unit
J604 J527 Steering column electronics control unit
J540 Electromechanical parking brake control unit
J583 NOx sensor control unit
J587 Selector lever sensors control unit
J604 Auxiliary air heater control unit
J605 Boot lid control unit
J623 Engine control unit
J667 Power output module for left headlight
J393 J668 Power output module for right headlight
J738 Telephone controls control unit
J743 Mechatronics for direct shift gearbox
G384 H12 J764 J745 Cornering light and headlight range control unit
G273 J788 Powertrain CAN bus isolation relay
R Radio
S340_002
T16 Diagnosis connection 16-pin connector
7
Data Bus Systems
Control Units for Powertrain CAN Data Bus

Control units and locations
The adjacent diagram shows the control units Headlight range control,
control unit J431,
that are involved in the powertrain CAN data
on right-hand side of
bus communication as well as their locations.
glove compartment
The data transfer speed is 500kbit/s. The transfer

occurs via the CAN high cable and the CAN low
cable. The CAN cables are twisted together for
secure data transfer.
The powertrain CAN data bus is not suitable for

use with a single cable data transfer would not
be possible if one CAN cable fails.
ABS control unit J104,

on the bulkhead,
on right inside engine compartment
Due to new terminology for the names

of components, some terms may be Adaptive cruise control unit J428 *,
different to those used in other behind the brand badge
self-study programmes.
* To be used at a later point in time.

Engine control unit J623,
under the plenum chamber cover
8
Selector lever sensors control unit J587,
under centre console at front
Airbag control unit,
under centre console at front
Four-wheel drive control unit J492 *,

on the Haldex coupling, in front of the rear axle
Steering column electronics control unit J527,

under the steering column switch
Data bus diagnostic interface J533,

on left under dash panel
Automatic gearbox control unit J217,

Power steering control unit J500, in front left wheel housing S340_004
on the steering rack near the
bulkhead
9
Data Bus Systems
Control Units for Convenience CAN Data Bus

Control units and locations Front passenger seat
position with memory
The adjacent diagram shows the control units J521,
that are involved in the convenience CAN data under passenger seat
bus communication as well as their locations.
The data transfer speed is 100 kbit/s. The transfer
The convenience CAN data bus is suitable for

use with a single cable data transfer would still
Door control units J386, J387, J388, J389,

in the doors
Convenience system central control unit J393,

on right under dash panel
Climatronic control unit J255,

in middle of dash panel
10
Parking aid control unit J446,
in the side section at rear right
Trailer detector control unit J345,
in the side section at rear left
Multifunction steering wheel control unit J453,

in the steering wheel
Steering column electronics control unit J527,

in the steering column
Seat and steering column adjustment control unit

with memory J136,
under drivers seat
Onboard power supply control unit J519, S340_005
on relay carrier under the dash panel
11
Data Bus Systems
Control Units for Infotainment CAN Data Bus

Combi and Diagnosis
Control units and locations
The adjacent diagram shows the control units
that are involved in the infotainment and combi
CAN data bus communication as well as their
locations.
Infotainment CAN data bus
The data transfer speed is 100 kbit/s. The transfer

The infotainment CAN data bus is suitable for

use with a single cable data transfer would still
Combi and diagnosis CAN data bus

CD changer R41,
The data transfer speed is 500 kbit/s. The in glove compartment
transfer occurs via the CAN high cable and the
CAN low cable. The CAN cables are twisted
together for
The combi and diagnosis CAN data bus systems

are not suitable for use with a single cable data
transfer would not be possible
if one CAN cable fails.
Auxiliary heater control unit J364,

in right wheel housing
12
Control unit with display for radio
and navigation J503,
in the dash panel
Mobile telephone operating electronics

control unit J412,
under passenger seat
Control unit with display in dash panel

insert J285
Digital sound package control unit J525,

under drivers seat
Data bus diagnostic interface J533,

in footwell on drivers side,
Diagnosis connector T16 near pedals
S340_007
on left under dash panel, drivers side
13
Data Bus Systems
Sub-bus Systems
LIN data bus
The Local Interconnect Network is a local system
that transfers data via a single-wire connection
at a data transfer rate of 1 - 20 kbit/s.
The transfer rate is stored in the master control
unit software. The data exchange occurs
between a master control unit and up to 16 slave
control units. The communication between the
individual subscribers is initiated exclusively by
the master control unit that can also
communicate on the CAN data bus.
Control Units for LIN Data Bus
J393 G384 G273 H12

G397
J533
J400
J519
S340_062
Legend
G397 Rain and light sensor
H12 Alarm horn
J519 Onboard power supply control unit
14
Electromechanical CAN data bus
The data transfer speed of the electromechanical

parking brake CAN data bus is 500 kbit/s.
The transfer occurs via the CAN high cable and
the CAN low cable. The CAN cables are twisted
together for secure data transfer.
The powertrain CAN data bus is not suitable for

use with a single cable data transfer would not
Control units for electromechanical parking brake CAN data bus
J104
J533 J540
S340_063
Legend
J533 Data bus diagnostic interface Additional CAN data bus systems are
J540 Control unit for electromechanical necessary due to the high
parking brake requirements (data rate and quantity).
15
Data Bus Systems
Cornering Lights (Advanced Frontlighting System) CAN Data Bus

The data transfer speed of the cornering light
CAN data bus is 500 kbit/s. The transfer occurs
via the CAN high cable and the CAN low cable.
The CAN cables are twisted together for secure
data transfer.
The cornering light CAN data bus is not suitable

for use with a single cable data transfer would
not be possible if one CAN cable fails.
Control units for cornering light CAN data bus
J668
J745
J533
J667
S340_064
Legend
J667 Power output module for left headlight
J668 Power output module for right headlight
J745 Cornering light and headlight
range control unit
16
Sensor CAN data bus
The data transfer for the sensor CAN data bus is the same as the cornering light CAN data bus and
transfers the data between the engine control unit and the NOx sensor control unit.
J583 J623
J533
S340_065
Legend
J583 NOx sensor control unit
Serial data bus

The serial data bus transfers the data via a single-wire connection at 9800 kbit/s between the electronic
steering column lock control unit and the convenience system central control unit. Using the serial data
bus system increases theft protection compared with use of the LIN data bus system.
J393
J533
J764
S340_066
Legend
17
Electronics Box
Location
The electronics box is mounted at the front right
in the engine compartment.
Description
All fuses and relays for protection and control of

the electrical components in the engine
compartment are accommodated in the
electronics box.
There is therefore no cable running into the

interior and back.
Troubleshooting is made easier, the protection is

configured better to the consumer and multiple
assignment of fuses is avoided to a great extent.
S340_010
Please refer to the ELSA electronic service information system for the current assignment
with fuses and relays in the electronics box.
18
Electronics Box
The electronics box also contains the following

relay in addition to the fuses for the components
in the engine compartment:
- Voltage supply relay

terminal 30 J317
S340_011
Back-up fuse box
The back-up fuse box contains the fuses for
- the alternator,
- the electromechanical power steering,
- the radiator fan,
- the ABS control unit.
S340_012
19
Relay Carriers and Fuse Boxes

Locations
The relay carrier and the onboard power supply
control unit are under the left-hand side of the
dash panel.
Relay carrier
The relays connected to the relay carrier depend

on the vehicle version and the equipment.
On vehicles with heated seats, the circuit
breakers for the heating elements (thermal fuses)
are also mounted on the relay carrier.
S340_008
Relay carrier on onboard power supply

control unit
There is an additional relay carrier on the

onboard power supply control unit.
S340_009
20
Left-hand fuse box
The fuse box is on the left-hand side of the dash

panel behind the cover.
S340_013
Right-hand fuse box
The fuse box is on the right-hand side of the dash

panel behind the cover.
S340_014
Please refer to the ELSA electronic service information system

for the current assignment of the fuses.
21
Onboard Power Supply Control Unit J519

Location
The onboard power supply control unit is on the
left underneath the dash panel and forms a unit
with the relay carrier.
S340_009
Versions
The Passat is equipped with two different versions
of the onboard power supply control unit.
High version
for vehicles with fog lights and/or Bi-Xenon
lights and customisation options.
Medium version
for all other vehicle variants.
Fog lights can be retrofitted only if the medium version of the onboard power supply control
unit is also exchanged for the high versions.
22
Tasks
The onboard power supply control unit switches and controls the following functions:
Outside light control with bulb monitoring Front windscreen wiper

The blown bulb is indicated by the The CAN data bus signals are forwarded from
corresponding warning light or as a text in the the onboard power supply control unit to the
dash panel insert. wiper motor control unit
Convenience lights with Rear windscreen wipers

When you select reverse gear, the rear
Coming Home windscreen wiper is switched on (estate only).
After the vehicle doors are closed, the area
surrounding the vehicle is illuminated by a Windscreen and rear window washer pump
lighting system on the vehicle.
Turn signal control
Leaving Home
The area surrounding the vehicle will be Electrical load management
illuminated by a lighting system when the car Switch-off under 11.8 V, as in Touran.
is unlocked with the remote control.
Outside light control
Dimmable instrument lighting
Heated rear windscreen
Gear selector lighting
Heated front windscreen
Interior light control
Terminal 30G, via which the interior lights are Terminal control
supplied with power, is switched by the The onboard power supply control unit
onboard power supply control unit. controls terminal 75x via the X-contact relief
relay. Terminal 15 is controlled via the relay for
Fuel pump supply voltage supply terminal 15 in the electronics
When you open the drivers door, the electrical box. Terminal 50 is controlled via the relay for
fuel pump is supplied by the onboard power voltage supply terminal 50 in the electronics
supply control unit with voltage. box.
After you start the engine, the voltage is
supplied by the engine control unit.
23
Exterior Lights
Front headlights
Design
The shape of the headlights is no longer the classic double round design. Large eyes are formed by
tubes around the dipped beam lights.
The large square full-beam reflector improves the full-beam performance considerably compared with
the Passat 1997.
H7 headlights
The basic headlights use halogen technology. H7

lights are used for both the dipped and
full-beam lights.
A voltage stabilising system used by the onboard
power supply control unit increases the life of the
bulbs.
S340_015
Xenon headlights
The Passat 2006 can be ordered with

optional Bi-Xenon headlights with cornering light
function.
S340_016
Xenon headlights are run with high-voltages of several 10,000 volts. Contact with this voltage
can be fatal.
Therefore make sure you follow the safety guidelines given in the ELSA
electronic service information system.
24
Tail lights
Design
The tail lights feature the double round light design. They are two-piece.
Tail lights in side section
The tail light, brake lights and indicators use

LEDs and are integrated in the side section.
The advantages of LEDs over bulbs are faster

response times, better signal formation and
greater homogeneity of the illuminated areas.
Tail lights in the boot lid
The rear fog light is on the left of the boot lid and S340_017
the reverse light is on the right.
Tail light and Tail light and Rear fog light
Normal bulbs are used here.
turn signal brake signal
Third brake light
A third brake light as well as the indicators

mounted in the door mirrors compliment the
headlights and tail lights and provide other road
users with additional visual signals.
The third brake light at the top of the rear

windscreen as well as the indicators in the door
mirrors use LED technology.
S340_018
Third brake light
The whole unit will need to be

replaced if individual LEDs are faulty.
25
Rotary light switch

In the midline and highline version of the onboard power supply control unit, the light switch is a
semiconductor element. It is therefore only used for activation. The lights are controlled by the onboard
power supply control unit output stage.
Rotary light switch without automatic

headlight control
The light in the light switch is illuminated when

terminal 75 is switched active.
S340_019
Rotary light switch with automatic

headlight control
The symbol for automatic headlights is

illuminated red when the light switch is set to
automatic headlight control.
When the switch is in the automatic headlight

control position and the rain and light detector
sensor has detected night-time or darkness, the
symbol will be illuminated green.
When the switch is in the automatic headlight

control position and the rain and light detector S340_020
sensor has detected day-time or light, the symbol
will be illuminated light green.
You will find further information on

use of the rotary light switch and the
warning lights in the Passat 2006
operating manual.
26
Indicator functions
The following indicator modes are available in the Passat 2006:

- Hazard warning lights - Central locking flashing
- Crash warning lights - Anti-theft alarm flashing
- Emergency stop warning lights
- Turn signals
- Lane change flash
The individual operating modes have different priorities. This allows a flash function to be activated even
though another one is in use.
Priority 1 Hazard warning lights Priority 4 Turn signals, lane change flash
Priority 2 Crash warning lights Priority 5 Anti-theft alarm flash,
Priority 3 Emergency stop warning lights central locking flash
Hazard warning lights Turn signals
The hazard warning lights on function is sent This function is realised in the onboard power
directly from the hazard warning light switch to supply control unit and by the steering column
the onboard power supply control unit. electronics control unit. It is activated with the
This information is not related to the status of turn signal switch.
terminal 15.
Lane change flash

Crash warning lights
If the turn signal switch is pressed for less than
The hazard warning lights are switched on 1 second, the indicators will flash three times.
automatically when the airbag control unit Pressing the turn signal switch in the same
recognises a crash. direction for less than one second will add three
more flashes.
The function can be activated with the
Emergency stop warning lights customisation options or the VAS tester.
The hazard warning lights are switched on in an

emergency braking situation Anti-theft alarm and central lock flash
(deceleration > 7 m/s2 longer than 700 ms) or
when the ABS is active for more than two These flash functions are requested by the
seconds. convenience system central control unit from the
This function needs to be activated in the onboard power supply control unit via the CAN
onboard power supply control unit using a data bus when the corresponding function is
VAS tester. active.
27
Exterior lights functional diagram
S340_021
Legend
D1 Immobilizer reading unit K1 Main beam warning lamp
E1 Light switch K4 Side light warning lamp
E2 Turn signal switch K6 Hazard warning light system warning lamp
E3 Hazard warning light switch K13 Rear fog light warning lamp
E4 Headlight dipper/flasher switch K18 Trailer operation warning lamp
E7 Fog light switch K65 Left turn signal warning lamp
E18 Rear fog light switch K94 Right turn signal warning lamp
E20 Switches and instruments illumination regulator K170 Bulb failure warning lamp
E22 Intermittent wiper switch L9 Light switch illumination bulb
E34 Rear wiper switch L22 Left fog light bulb
E38 Intermittent wiper regulator L23 Right fog light bulb
E44 Washer pump switch L46 Rear fog light bulb
(automatic wash/wipe and L76 Button illumination bulb
headlight washer system) L131 Exterior mirror turn signal bulb,
E102 Headlight range control regulator drivers side
E415 Entry and start authorisation switch L132 Exterior mirror turn signal bulb,
F Brake light switch front passenger side
F4 Reversing light switch M1 Left side light bulb
F266 Bonnet contact switch M2 Right tail light bulb
J285 Control unit with display in dash panel insert M3 Right side light bulb
J362 Immobilizer control unit M4 Left tail light bulb
J386 Driver door control unit M5 Front left turn signal bulb
J387 Front passenger door control unit M6 Rear left turn signal bulb
J393 Convenience system central control unit M7 Front right turn signal bulb
J519 Onboard supply control unit M8 Rear right turn signal bulb
J527 Steering column electronics control unit M9 Left brake light bulb
J533 Data bus diagnostic interface M10 Right brake light bulb
28
S340_069
M17 Right reversing light bulb Input signal

M25 High level brake light bulb Output signal
M29 Left dipped beam bulb
Positive
M30 Left main beam bulb
Earth
M31 Right dipped beam bulb
M32 Right main beam bulb Data bus
N360Steering column lock control element
N376 Ignition key withdrawal lock solenoid
S Fuse
V48 Left headlight range control motor
V49 Right headlight range control motor
W31 Front left entry light
W32 Front right entry light
X Number plate light
29
Automatic headlight control

Dusk function E415 G397
If light switch E1 is set to automatic headlight

control, the rain and light detector sensor G397
automatically measures the light, e.g. when
entering a tunnel, and sends a signal to the
onboard power supply control unit to
automatically switch on the driving lights.
Legend
E1 Light switch
E415 Entry and start authorisation switch E1
G397 Rain and light sensor J519
L123 Left dipped beam bulb
L124 Right dipped beam bulb
L125 Left main beam bulb
L126 Right main beam bulb
L124 L126 L123 L125

S340_067
Motorway function
The motorway function switches the driving lights

on when the car travels faster than 140 km/h for
over 10 seconds. They are switched off again
when the car travels slower than 65 km/h for
longer than 150 seconds. The function is
activated when the light switch is set to
automatic headlight control.
S340_022
Rain function
The rain function switches the driving lights on

when the front wipers are active for longer than
5 seconds and the light switch is set to automatic
headlight control. The driving lights are switched
off again when there is no wipe procedure for
longer than 255 seconds.
S340_023
30
Vehicle lights
Emergency light mode
If the onboard power supply control unit is not capable of controlling the car lights due to a processor
malfunction, an additional piece of hardware will take over the following lights:
- Brake light
- Side light
- Dipped beam
Light functions
The following lights have additional functions:
Lights Additional functions

Rear left and right brake lights Dimmed switch on as tail light
dimmed to 10%
Rear left and right indicator Dimmed switch on as tail light

dimmed to 15%
Light switch delay
The delay prevents the headlights being switched on briefly in the automatic headlight control position
when you quickly turn the switch from the off position to the side lights or headlights position.
From/to Off Automatic Side light Driving lights

headlight control
Light Sensor signal Light Sensor signal Light Sensor signal Light Sensor signal
Lights on Lights off Lights on Lights off Lights on Lights off Lights on Lights off
(ms) (ms) (ms) (ms) (ms) (ms) (ms) (ms)
Off 500 0 0 0 0 0
Automatic 0 0 600 0 0 0
headlight control
Side light 0 0 500 0 0 0
Driving lights 0 0 0 0 600 600
31
Data Bus Diagnostic Interface J533

Function
Due to the high proportion of networked
functions, large quantities of data have to be
transferred.
To ensure trouble-free data exchange, several
data bus systems are required to exchange data
between each other.
The data bus diagnostic interface links these

data buses as a gateway interface and allows
data transfer.
Location
The data bus diagnostic interface is on the left
under the dash panel, above the accelerator
pedals.
Master functions
The data bus diagnostic interface J533 takes over
the master functions for terminal 15 run-on on the
powertrain CAN data bus as well as the control
logic for sleep and wake-up mode of the data
bus systems.
S340_028
For more information on the data bus diagnostic interface, see

SSP 307 The Touran Electrical System.
32
Transport mode
The car battery can be discharged during long transportation and standing times due to no-load
currents.
Transport mode is activated to keep power consumption as low as possible. Control unit with display in
dash panel insert J285 indicates that transport mode is active.
While transport mode is active, the car can be started and can be driven normally. The following
convenience and infotainment consumers are deactivated:
Central locking Receiver for auxiliary heater remote start

Window regulators Inclination sensor
Radio Save LED in the door
Multifunction steering wheel Interior lights after 30 seconds active
Remote control Seat memory
Interior monitoring Air conditioning
Deactivate transport mode
Transport mode can only be switched off with the

VAS diagnostic testers via the vehicle
self-diagnosis (collection services).
It is automatically disabled after
a distance > 50 km.
Activate transport mode
Transport mode can only be switched on with the

VAS diagnostic testers via the vehicle
self-diagnosis (collection services).
It can only be activated within the first 150 km.
S340_029
33
Control Unit with Display in Dash Panel Insert J285

Function
The control unit with display in dash panel insert receives its information for the display unit and warning
lights from the various control units via the data bus diagnostic interface J533 and via the combi CAN
data bus.
External sensor signals still reach the control unit in the dash panel insert from the following sensors via
discrete wiring:
- F1 Oil pressure switch - G33 Windscreen washer fluid level sender

- F9 Handbrake warning switch - G34 Brake pad wear sender
- F34 Brake fluid level warning contact - G266 Oil level and oil temperature sender
- G17 Ambient temperature sensor - J538 Fuel pump control unit
- G32 Coolant shortage indicator sender
F34
G17
G32 E24
G33
G266
F9 G34
J538
F1
S340_030
34
Variants
The gauges in the display in the dash panel insert Y24 are divided into three versions.
Lowline version
The lowline version has eight

LED warning lights (E) and a semi-dot liquid
crystal display (LCD) (F).
A C D B E F
S340_031
E
Midline version
The midline version has eight

LED warning lamps (E), a mini-dot display (F), a
semi-dot LCD in the speedometer (O) and in the
rev counter (N). F
N O S340_032
Highline version
The midline version has a

dot-matrix display (K), a semi-dot LCD in the
speedometer (O) and in the rev counter (N).
K
N O S340_033
Common equipment
All versions have:
- Rev counter (A) G5

- Speedometer (B) G21
- Coolant temperature gauge (C) G3
- Fuel gauge (D) G1
35
Equipped with warning lamps
Symbol Warning lamp Lowline Midline Highline Warning text or warning

Airbag X X X Airbag fault
Airbag Belt tensioner deactivated
ABS X X X ABS
(anti-lock brake
system)
Brake pad wear X X Pictogram Check brake pad
Brake fluid low X X X Stop brake fluid

Owners manual
Preheat X X X Engine fault Workshop!

(diesel engines) Emissions Workshop!
or
Electronic Power X X X Engine fault Workshop!

Control Emissions Workshop!
Dynamic Flashing Flashing Flashing Stop Oil pressure Engine off
oil pressure warning Pictogram Owners manual
3 x warning buzzer
Diesel particle filter X X Pictogram
Power steering X X X Steering lock fault!

Electronic Power Lock steering!
Steering Move steering!
Steering lock! Workshop!
Electronic X X X 3 x warning buzzer
brake pressure
distribution
Parking brake / X X X Handbrake on
electromechanical Release parking brake by hand!

parking brake Depress brake pedal!
Electromechanical X X X Parking brake fault!
parking brake Owners manual!
Warning lamp
ESP X X X
TCS
Left-hand indicator X X X Acoustic signal
Right-hand indicator X X X Acoustic signal
Trailer turn signals X X X
Main beam X X X
Cruise control X X X
36
Icon Warning lamp Lowline Midline Highline Warning text or warning
Bulb failure X X e.g. Front left dipped beam defective!
Constantly illuminated: Faulty bulb
Flashing: HRC or AFS faulty
Boot lid X X Pictogram e.g. Boot lid open!

1 x warning buzzer at
speed of > 6 km/h
Door open X X Pictogram Drivers door open! Passenger door open!

Rear left door open! Rear right door open!
1 x warning buzzer at
speed of > 6 km/h
Fuel reserve X X Pictogram Please refuel

1 x warning buzzer
Coolant low or X X Pictogram Stop! Check coolant Owners manual

overheating 3 x warning buzzer
Alternator X X X
Engine check X X X Engine fault Workshop!

EOBD Emissions Workshop!
Bonnet open X X Pictogram Door warning! Hood!

1 x warning buzzer when v > 6 km/h
Rear fog lights X X X
Oil level X X Pictogram Check oil level

Oil sensor Workshop!
Tyre pressure X X X 1 x warning buzzer

monitoring
Shift lock X X X
Seat belt X X X Please fasten seatbelt

Gong
Day driving lights X X X
Fuel cap open X X X
Wash fluid low X X X Top up wash fluid

1 x warning buzzer
37
Convenience System Central Control Unit J393

Location
The convenience system central control unit is
located under the dash panel, on the right
behind the glove compartment.
Tasks
The convenience system central control unit
activates and controls the following functions:
S340_034
- Central locking control unit
- Activation of rear door control units
- Activation of the fuel tank flap release
- Activation of the boot lid release
- Activation of the anti-theft alarm via
LIN bus
- Activation of the tyre pressure monitor
- Activation of the immobilizer
- Activation of the entry and
start authorisation system.
In the Passat 2006, the tyre pressure monitoring (via tyre pressure sensors and tyre pressure monitor
aerials), immobilizer control unit J362 and entry and start authorisation control unit J518 functions are
combined in the convenience system central control unit for the first time.
Furthermore the convenience system central control unit is the master control unit in the LIN anti-theft
alarm data bus. The anti-theft alarm system includes the interior monitoring sensor G273, the intelligent
anti-theft alarm system horn H12 and the vehicle inclination sensor G384.
38
Central locking
The convenience system central control unit controls all central locking functions.
The central locking system includes the doors, the boot lid and the tank filler flap.
There are three locking states.
Unlocked The doors can be opened from the inside and outside.
Locked The doors can only be opened from the inside by pulling the door
handle once.
Safe The doors cannot be opened either from the inside or the outside.
Locking points
It is operated by the emergency lock cylinder in the drivers door, the interior locking button and the
remote control on the car key.
The motors for the central locking in the drivers and passenger door are controlled by the respective
door control units. The control of the rear doors, the boot lid and the tank filler flap is handled by the
convenience system central control unit.
Operating central locking
If the vehicle is locked via the interior locking button, the LED integrated in the button will illuminate.
The doors can be opened from the inside by pulling the door handle once.
When individual door opening is activated, opening the car mechanically with the car key only unlocks
the drivers door. Turning the key twice also only operates the door control unit on the drivers side.
Pressing the OPEN or CLOSE button more than 200 times outside the reception range of the
convenience system central control unit blocks the remote control unit. The remote control needs to be
re-activated by pressing the OPEN button and then unlocking the car with the car key
(within one minute).
39
Immobilizer IV
What does the immobilizer IV Central FAZIT database
comprise?
The immobilizer IV is not a separate control unit, The central FAZIT database at Volkswagen in
but a function. Wolfsburg is a essential component of the
It includes: immobilizer IV.
FAZIT stands for Fahrzeugauskunft- und
Storage of all theft-related features of the zentrales Identifikations-Tool (Vehicle
control units in the FAZIT central database in Information and Central Identification Tool). All
Wolfsburg. theft-related data from the control units that are
integrated in the Immobilizer function are
Communication of the convenience system
stored in this database.
central control unit, in which the immobilizer is
integrated, with the other components It is not possible to adapt the control units used
involved. without an online connection to FAZIT.
Encryption of the data communication
between the individual control units.
S340_036
40
Data Transfer
Only an online query by the diagnostic tester All components involved in the immobilizer
transfers the data safely, quickly and reliably have to be taught online.
in the car. All car keys (including replacements) are
A PIN query of the immobilizer components by already pre-coded at the factory for a specific
fax or prior enabling of the components is not car and can only be taught for this vehicle.
possible.
Data Transfer
VAS 5051
FAZIT
J533 J393
S340_037
Legend
J393Convenience system central control unit
J533Data bus diagnostic interface
41
Immobilizer components
Convenience system central control unit Entry and start authorisation switch (E415)
J393
The immobilizer function is integrated in the The entry and start authorisation switch contains
convenience system central control unit. the reader coil for reading the transponder in the
The control unit needs to be adjusted online after car key. The switch for entry and start
a replacement. authorisation does not need to be adjusted after
changing.
Electronic steering column lock control unit Engine control unit J623
J764
The approval for locking and unlocking the The engine control unit is part of the
steering column is provided via the Immobilizer Immobilizer function. Authorisation via the
function in the convenience system central CAN data bus from the convenience system
control unit. central control unit is required for continuous
The control unit can only be replaced and running of the engine. This control unit needs to
adjusted together with the convenience system be adjusted online after a replacement.
central control unit.
E415
J623
J527
J393
J764
S340_038
Legend
E415 Entry and start authorisation switch Reader coil line
J527 Steering column electronics control unit Powertrain CAN data bus
J623 Engine control unit S contact
J764 Electronic steering column
lock control unit Coded voltage supply signal
42
Replacement of control units
Control units that are involved in the Immobilizer function can only be replaced with an online
connection to the FAZIT database.
Convenience system central control unit Engine control unit J623

J393
Request data via online connection Request data via online connection
Data transfer via VAS tester Data transfer via VAS tester
Download data into control unit Download data into control unit
Teach control unit Data exchange between control unit and
Teach car key FAZIT
Teach car key
Electronic steering column lock control unit J764 and

convenience system central control unit J393
Request data via online connection Data exchange between control units and
Data transfer via VAS tester FAZIT
Download data into control unit Teach car key
J764
VAS 5051
FAZIT J393
J533
J623
S340_040
Legend
J393 Convenience system central control unit J623 Engine control unit
J527 Steering column electronics control unit J764 Electronic steering column
J533 Data bus diagnostic interface lock control unit
43
Start-Stop System
Entry and start authorisation switch
The entry and start authorisation switch is part of
the driving authorisation system. It is used as a
mechanical holder for the ignition key, converts
the push movement of the ignition key into
electrical signals and picks up the reader coil for
electronic identification of the ignition key.
S340_044
Key ignition
The ignition key does not have a key bit as the
car is started with a pushing movement for the
first time, not by turning.
Releasing the
emergency key
S340_042
Emergency key
The emergency key is used to open the drivers
door mechanically if you cannot open it with the Emergency key
remote control.
It is inserted in the ignition key. Also the key ring
holder is attached to it. It can be used when the
emergency key is in the second notch.
S340_043
44
Key positions
The various terminal voltages (terminal S,
terminal 15) are activated and the start
procedure is initiated by pushing the ignition key
into the entry and start authorisation switch.
S340_041
Switch positions
The following switch positions can be set by
pushing the ignition key:
- P0 Off
- P1 S contact on S340_045
- P2 Terminal 15 on
- P3 Terminal 15 drive
(the ignition key automatically moves P0 P1 P2 P3 P4
to this position after starting)
- P4 Terminal 50 on
Functional Diagram
Legend
D1 Immobilizer reading unit
D2 Immobilizer reader coil
E415 Entry and start authorisation switch
J362 Immobilizer control unit
N376 Ignition lock withdrawal solenoid lock
S340_046
45
Electronic Steering Column Lock Control Unit

Control unit
The electronic steering column lock is supplied
with power by the convenience central control
unit J393. Locking and unlocking as well as
diagnosis is controlled with the convenience
system central control unit via a serial data bus
connection.
To take the increased safety requirements into

account, the electronic steering column lock
release needs to be authorised by three separate
control units.
S340_047
Lock/unlock
The following conditions need to be met:
An authorised key needs to be recognised by Convenience system central control unit J393
the immobilizer. (terminal 15 off; CAN signals from J533 and
J527 OK)
Data bus diagnostic interface J533
(speed = 0 km/h; revs = 0 rpm) Entry and start authorisation switch E415
(S contact off, terminal 15 off)
Steering column electronics control unit J527
(terminal 15 off; speed = 0 km/h) Electronic steering column lock control unit
J764
(checks whether both speed signals from J533
and J527 are OK)
The electronic steering column only unlocks when an authorised key is recognised by the
immobilizer.
Terminals 15 and 50 are only activated once the electronic steering column lock has been
released.
46
Functional Diagram
J527
J386
J519
J393
J285
J533
E415
J764
J623 J104
S340_048
Legend
E415 Entry and start authorisation switch CAN data bus
J285 Control unit with display in dash panel insert Output signal
J393 Convenience system central control unit Input signal
Plus
J533 Data bus diagnostic interface Serial data bus
47
Convenience and safety electronics
Cornering Light System (Advanced Frontlighting System)

A cornering light system is optionally available
for the Passat 2006.
Dynamic cornering lights

The dynamic cornering lights are adjusted to the
steering angle during cornering and therefore
guarantee optimum road illumination in all
driving situations.
S340_024
Static cornering lights

The static cornering light is particularly useful
when you turn off at crossroads and into side
roads. An additional bulb in the headlights is
switched on for this.
S340_025
You will find further information on the cornering lights in SSP 335
Cornering Light System
48
Dynamic cornering light operation
The dipped beam bulb module is swivelled
horizontally by an integrated electric motor.
Swivelling angle
15
The swivelling angle is approx. 15 degrees for the
outside headlight and approx. 7.5 degrees for the 7.5
inside headlight in the curve.
7.5
15
S340_026
Illumination
Curves are illuminated better due to the varying
swivelling angles. The maximum possible
illumination is reached by the headlight on the
inside of the curve swivelling in twice as far as
the headlight on the outside of the curve.
S340_027
At driving speeds under 10km/h, the bulb modules are not swivelled.
Over 10km/h, the swivelling angle is basically dependent on the curve radius. The legal
requirements stipulating that the headlights may be not swivelled while the vehicle is
stationary are therefore fulfilled. Also, the headlights are swivelled slightly when the vehicle
accelerates from a standstill and the steering angle remains constant.
49
Convenience and safety electronics
Customisation
Customisation options allow customers to make The system is operated using the lever on the
their own settings for convenience and steering wheel and the menus are selected using
infotainment functions. the display in the dash panel insert Y24.
The settings you select are stored in the control
The specific settings for the different equipment unit that is responsible for control of the
functions are made using a control element and respective function.
a display.
The necessary information is transferred between
the control unit in the dash panel insert and the
respective control units via the CAN data bus.
Control units involved in customisation

Y24
J412
J285
J453
J364
J533 J503
J527
R
G397 J519 J393 J386 . J389
J400 S340_053
Legend
G397 Rain and light sensor J453 Multifunction steering wheel control unit
R Radio J503 Control unit with display for radio and
J285 Control unit with display in dash panel insert navigation
J364 Auxiliary heater control unit J519 Onboard supply control unit
J386..J389 J527 Steering column electronics control unit
Door control units J533 Data bus diagnostic interface
J393 Convenience system central control unit Y24 Display in dash panel insert
J412 Mobile telephone operating electronics control unit
50
For example: Menu guide
Lights & Vision

Coming Home
Leaving Home
Footwell light
Lane change flash
Wipers
Factory setting
Back
Lane change flash Off Lane change flash on
On On
Off Off
Back Back
Lane change flash on Lane change flash off
On On
Off Off
Back Back
Lane change flash off Short press of button
Long press of button

On
Off
Back
S340_054
51
Parking Aid
The parking aid supports the driver when
manoeuvring and parking.
It is based on the familiar 8-channel ultrasound
technology.
Parking aid control unit J446

The parking aid control unit J446 is located in the
boot at the rear right.
S340_055
Parking aid button E266

The parking aid button is on the right next to the
selector lever or gearstick. The parking aid is
activated when you press the button or select
reverse gear.
It is switched off when you press the button again

or automatically at a speed > 15 km/h.
The LED in the button turns yellow when the

parking aid is active. If the LED is flashing, a fault
has been detected.
S340_056
Parking aid button
52
Parking aid sender
The senders are mounted in the rear and front bumpers as well as the radiator grille.
Signal flow diagram
J285
Front Rear
3
G252 G206
J217 J345
2 4
E266
G253 G205
7
J533
1 5
6
G254 J104 J519 G204
9 8
J446
G255 G203
11 Terminal 30
10 Terminal 15
H22 H15
S340_057
Legend Signal flow

E266 Parking aid button 1 Wheel speed from J104 to J446 via J533.
G203Rear left parking aid sender 2 Selector lever position J217 to J446 via J533.
G204Rear centre left parking aid sender 3 Vehicle speed from J285 to J446 via J533.
G205Rear centre right parking aid sender 4 Trailer detection from J345 to J446
G206Rear right parking aid sender If a trailer is detected, only the front senders will be
G252 Front right parking aid sender active.
G253 Front centre right parking aid sender 5 Terminal 15 on and reversing light on from J519 to J446
G254 Front centre left parking aid sender 6 Fault detected from J446 to J533
G255 Front left parking aid sender 7 E266 pressed
H15 Rear parking aid warning buzzer 8 Signals from the rear parking aid senders
H22 Front parking aid warning buzzer 9 Signals from the front parking aid senders
J104 ABS/ESP control unit 10 Trigger H15
J217 Automatic gearbox control unit 11 Trigger H22
J285 Control unit with display in dash panel insert
J446 Parking aid control unit
53
Transformer
The Passat 2006 can be ordered with an
optional 230 V/50 Hz electrical socket.
A transformer has been installed in the car to
produce the alternating voltage. It is
permanently connected to the socket.
This unit is located in the centre console in place
of the cupholder.
S340_006
Transformer Electrical socket
Electrical socket
The 230 V socket does not have an earth
connector and can only be operated with a
maximum continuous output of 150 W. Approx.
300 W can be supplied as a short peak output
(2 min).
The socket has a built-in child protection device,
which also functions as a switch.
A green LED above the socket shows that is
working properly. If this LED flashes red, there is
a fault.
This can occur when the output exceeds 150 W
for a long period (overtemperature cut-off) or
the load draw is too high (greater than 300 W).
S340_058
No repairs may be carried out on 230 Volt systems.

Therefore the whole module needs to be replaced when the socket or transformer is faulty.
54
The socket is only powered when the engine is
running (terminal 61). Except for the signal cable
from the onboard power supply control unit, the Child protection
transformer is connected to the onboard power micro switch
supply control unit with a voltage supply
(terminal 30) and an earth point.
The alternating voltage stage is electrically Transformer
isolated.
Status LED
S340_061
The following appliances can be run with the

transformer,
for example:
Notebook power supply 75-110 W

Games console 40-100 W
Bulb 25-100 W
Television ~85 W
Baby bottle warmer ~80 W
Battery charger ~50 W
Mobile phone charger ~30 W
DVD player ~30 W
Shaver ~10 W S340_059
The following appliances cannot be run with the

transformer,
for example:
Hairdryer > 1000 W

Vacuum cleaner > 800 W
Coffee machine > 500 W
Appliances with an earth connection
Work lights with neon tubes
S340_060
55
Service
Wiper Adapter Systems
Two new adapter systems are used for the wipers on the Passat 2006 called the side-lock
and top-lock systems. Both systems allow you to replace the wiper blades in the parked
position and ensure a more stable connection to the wiper arm.
Side-lock adapter system
S340_074
Top-lock adapter system
S340_075
56
Washer Fluid Hose
The Passat 2006 features an improved connector system for the washer fluid hose.
Release
Washer fluid hose connector
Lock
S340_076
Please refer to the ELSA electronic service information system for specific instructions on
replacing wiper blades and separating the connectors.
57
Test Yourself
1. What is the maximum appliance output that can be connected constantly to the 230 V socket?
a) 100 W
b) 150 W
c) 300 W
d) 150 W, but only for 2 minutes
2. Which functions are not integrated in the new convenience system central control unit?
a) Immobilizer
b) Tyre pressure monitoring
c) Central locking
d) Transformer
3. Which light systems are used in the new Passat tail lights?
a) LEDs only
b) Bulbs only
c) Bulbs in the side section, LEDs in the boot lid
d) LEDs in the side section, bulbs in the boot lid
58
4. Which components have to be adjusted using the FAZIT database?
a) Convenience system control unit
b) Electronic steering column lock control unit
c) Engine control unit
d) Onboard supply control unit
5. Where is the entry and start authorisation switch?
a) In the door handle
b) In the dash panel
c) In the boot
d) In the drivers door, next to the window switches
6. How many sensors does the Passat 2006 parking aid system have?
a) 4 sensors, just at the rear
b) 6 sensors at the front, 6 sensors at the rear
c) 4 sensors at the front, 4 sensors at the rear
d) 6 sensors, just at the rear
Answers: 1 b; 2 d; 3 d; 4 a, b, c; 5 b; 6 c
59
340

All rights and rights to make technical alterations reserved.
000.2811.55.20 Technical status 02/2005
Volkswagen AG
Brieffach 1995
38436 Wolfsburg
This paper was manufactured from pulp that was bleached without the use of chlorine.
Service Training
Karosserie Passat 2006

Body, Carrocera, Carrozzeria, Carrosserie
Karosserie
Mae und Gewichte 4 Sitze 19-20
Stofnger vorn/Kotflgel 5-6 Tankdeckel 21
Motorhaube und Haubenschloss 7 Heckdeckel 22-23
Tren 8-10 Scheinwerfer und Leuchten 24
Stofnger hinten 11 Hinweisschilder 25
Schalttafel, Anbauteile und Klebeverbindung 26-27
Innenraumverkleidung 12-14 Akustikmanahmen 28
Verglasung 15 Hohlraumkonservierung 29
Schutzleisten und Dachtrger 16 Rohbau-bersicht 30-31
Schiebe-/Ausstelldach 17 Karosserie-Reparatur-Gruppe 50, 51, 53 32-35
Airbag 18
Body
Dimensions and weights 4 Seats 19-20
Front bumper/Body wings 5-6 Tankflap 21
Bonnet 7 Rear lid 22-23
Doors 8-10 Headlamps and lights 24
Rear bumper 11 Notice sticker 25
Dash panel, ancillaries and Adhesive joints 26-27
interior trim 12-14 Acoustic measures 28
Glasing 15 Cavity sealing 29
Door trim and roof rack 16 Overview of body shell 30-31
Sliding/tilting sunroof 17 Body repair group 50, 51, 53 32-35
Airbag 18
Carrocera
Dimensiones y pesos/aerodinmica 4 Asientos 19-20
Paragolpes delantero 5-6 Tapa del dposito 21
Cap del motor y cerradura del cap 7 Portn traservo 22-23
Puertas 8-10 Alumbrado 24
Paragolpes trasero 11 Adhesivos 25
Tablero de instrumentos, componentes y Uniones pegadas 26-27
guarnecidos del habitculo 12-14 Medidas acsticas 28
Cristales 15 Conserveracin de cavidades 29
Bajos y moldras laterales 16 Carrocera sin elementos mviles,
Techo corredizo/deflector 17 cuadro sinptico 30-31
Airbag 18 Reparacin de carosceria - grupo 50, 51, 53 32-35
Carrozzeria
Dimensioni e masse/aerodinamica 4 Sedili 19-20
Paraurti anteriori 5-6 Tappo del serbatoio carburante 21
Cofano vano motore e relativa serratura 7 Portellone posteriore 22-23
Porte 8-10 Luci 24
Paraurti posteriori 11 Targhette instruzioni 25
Cruscotto, parti applicate e Connessioni adhesive 26-27
rivestimenti abitacolo 12-14 Provedimenti riguardanti Iacustica 28
Vetri 15 Protezione delle cavit 29
Sottoscocca e modanature protettive 16 Vista dinsieme della scocca grezza 30-31
Tettuc cio scorrevole/Sollevabile 17 Carrozzeria -riparazioni - gruppo 50, 51, 53 32-35
Airbag 18
Carrosserie
Cotes et poids 4 Siges 19-20
Pare-chocs avant 5-6 Bouchon de reservoir 21
Capot-moteur et serrure de capot-moteur 7 Hayon 22-23
Portes 8-10 Phare 24
Pare-chocs arrire 11 Plaquettes indicatrices 25
Tableau de bord, pices boulonnes Assemblages par collage 26-27
garniture et habillages dans Ihabitacle 12-14 Mesures dinsonorisation 28
Vitrages 15 Protectio des corps creux 29
Soubassement et baguettes de protection 16 Assemblage-tlerie: vue densemble 30-31
Toit coulissant/pivotant 17 Groupe de rparation carosserie 50, 51, 53 32-35
Coussins gonflables 18
P 3
Karosserie
cw = 0,281
4 P
P 5
Karosserie
6 P
P 7
Karosserie
8 P
P 9
Karosserie
10 P
P 11
Karosserie
12 P
P 13
Karosserie
14 P
P 15
Karosserie
16 P
P 17
Karosserie
18 P
3
1 4
P 19
Karosserie
20 P
P 21
Karosserie
22 P
P 23
Karosserie
24 P
P 25
Karosserie
26 P
P 27
Karosserie
28 P
P 29
Karosserie
30 P
P 31
Karosserie
32 P
P 33
Karosserie
34 P
P 35
Alle Rechte sowie technische nderungen vorbehalten.
Technischer Stand 12.2004
Volkswagen AG
Brieffach 1995
38436 Wolfsburg
Dieses Papier wurde aus chlorfrei gebleichtem Zellstoff hergestellt.

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Volkswagen Passat B6 2005 - >

Interior rearview mirror

The automatically dimming interior rearview mirror dims

It consists of a mirror element and an electrical element

The electronic element registers light incidence from the

The applied current changes the color of the electrolytes.

The dimming function cuts out when reverse gear is

Interior rearview mirror with rain sensor, removing and

- In vehicles with rain sensor, switch ignition off.

- Remove left - 1 - and right cover caps -

- Carefully slide rearview mirror - 3 - ,

- Operate connector socket locking tabs

- Installation is performed in the reverse order of removal.

Holding plate for interior rearview mirror with rain

Removal of windshield is no longer necessary, as with

At the same time, it is possible to re-use the old, detached

- All adhesive and primer residue must be removed up to

- Clean adhesion surface using cleaning solution D 009

- Dry off period must be at least 10 minutes.

- Apply glass-/paint primer D 009 200 02 .

- Dry off period until bonding: at least 10 minutes to a

Preparing detached and new mirror base

- Use a tool to remove adhesive residue (only for detached

- Prepare adhesive surface by wet-sanding with fine emery

- Then clean using cleaning solution D 009 401 04 .

Bonding mirror base

- Apply two part polyurethane adhesive D 180 KD2 A1

- Adhesive bead diameter: approx. 2.5 to 3 mm.

- Immediately after applying adhesive on mirror base,

- Align mirror base on its designated position on ceramic

Cleaning and removing excess adhesive

- Carefully remove adhesive tape 0.5 to 1 hour after

- Remove excess soft adhesive all around using spatula.

- Then remove any remaining excess adhesive using a

Installation of rain sensor and mirror

- Mirror can be installed 2.5 hours after mirror base has

Interior rearview mirror, removing and installing

- Rotate interior mirror - 1 - 90

- Installation is performed in the reverse order of removal.

Holding plate for interior rearview mirror without rain

Glass/metal glue set D 000 703 A1 (interior mirror,

1 - Window scraper (commercially available)

- Remove retaining plate from mirror base.

- Remove PUR adhesive material from retaining plate with

- Grind the three spacer knobs off of adhesive surface. To

- Keep sanded surface free of dirt and grease.

- Scrape off PUR adhesive and primer from windshield

- Clean adhesive surface with adhesive remover D 002

Do not damage ceramic layer. Scratches always

- Cut nylon mesh to exact dimensions of mirror base.

Protective gloves (rubber gloves) should be worn.

- Spread thick layer of adhesive evenly on mirror base.

- Lay nylon mesh on mirror base.

- While continuing to apply adhesive with tube dab nylon

30 seconds are available from laying the nylon mesh on

- Press mirror base (without force) onto windshield and

- Use a rag to remove excess adhesive.

Mirror can be installed after 15 minutes.

Storage compartments, covers and trim

Required special tools, workshop equipment, testing and

Trim removal wedge 3409

Torque wrench V.A.G 1783

Center console (without foldable armrest), removing and