VOLKSWAGEN PASSAT CC 2009 (02) PDF Document

The VOLKSWAGEN PASSAT CC 2009 can be equipped with different types of maintenance-free batteries. The two main types described are:

1. Battery with magic eye:

This is a maintenance-free wet battery with liquid electrolyte. It is equipped with a “magic eye” that provides information about the electrolyte level and the charge state through a coloured display. It is important not to remove any stickers or replenish it with distilled water; only a visual check is required.

WARNING: Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! These batteries must be renewed due to the danger of explosion.

2. Absorbent Glass Mat (AGM) battery:

This is a maintenance-free battery with a contained electrolyte and no magic eye. It is a lead-acid battery where the electrolyte is held within a microscopic glass mat. The battery is sealed and fitted with valves. AGM batteries are identified by the abbreviation “AGM” on the battery itself. If you are replacing an AGM battery, it must be replaced with another AGM battery.

When handling the battery on your VOLKSWAGEN PASSAT CC 2009, observe the following critical safety warnings to prevent injury and damage:

Personnel Safety:

• Untrained personnel should only work on batteries under the supervision of a qualified vehicle mechanic or electrician.

• Acid is highly corrosive. Always have a neutralizing solution, like soap solution, available to treat acid burns.

• Leaking electrolyte can cause skin burns and corrosion on the vehicle, potentially damaging safety-relevant components.

Explosion Hazard:

• The gas formed during charging is explosive. An improperly handled battery may explode.

• It is prohibited to cause sparks, use naked flames, or smoke near batteries. This includes sparks from grinding, welding, or electrostatic charge. Always touch the vehicle body before touching the battery to discharge static electricity.

• Batteries with a colourless or light yellow magic eye must be renewed immediately. Do not check, charge, or jump-start them, as there is a high danger of explosion.

Work Environment:

• Only work on batteries in well-ventilated and suitable rooms.

The safety markings on the battery of your VOLKSWAGEN PASSAT CC 2009 indicate the following precautions:

1. No Fires/Sparks: Fires, sparks, naked flames, and smoking are prohibited. Avoid sparks from electrical units and short circuits. Never lay a tool on a battery.

2. Eye Protection: Wear eye protection before working on the battery.

3. Keep Children Away: Keep children away from acid and batteries.

4. Proper Disposal: Old batteries are hazardous waste and must be disposed of at a suitable collection centre according to legislation.

5. No Household Waste: Never dispose of old batteries in the household waste system.

6. Explosion Danger: A highly explosive gas is produced when batteries are charged.

7. Follow Instructions: Always follow instructions on the battery and in the owner’s manual.

8. Caustic Acid: Battery acid is very caustic. Wear eye protection and gloves. Do not tilt the battery, as acid can leak from the gas vents.

To prevent damage to the battery clamps and terminals on your VOLKSWAGEN PASSAT CC 2009, follow these instructions for connection:

• The battery clamps should only be fitted by hand and without using force.

• Battery terminals should not be coated with grease.

• The battery clamps should be fitted so that the battery terminal is either flush with the clamp or protruding from it.

• Once the battery clamps have been tightened to the specified torque, the threaded connections should not be tightened any further.

Performing a visual inspection of the battery on your VOLKSWAGEN PASSAT CC 2009 is essential before conducting more extensive tests. This check helps establish:

1. Housing Condition:

• Check if the battery housing is damaged. If it is, electrolyte (battery acid) can leak out, causing serious damage to the vehicle. Components affected by leaked acid should be treated immediately with an acid neutraliser or a soap solution.

2. Terminal Condition:

• Check whether the battery terminals (wire connections) are damaged. Damaged terminals can prevent proper contact with the battery clamps. When connecting clamps, tighten them to the torque specified in the workshop manual. Incorrectly seated or tightened clamps can cause the wiring to burn and lead to electrical system malfunctions.

3. Secure Mounting:

• Ensure the battery is secured correctly. Vibrations can shorten the battery’s life, damage cell plates, and potentially damage the housing, creating a risk of explosion.

• Check that the battery is securely seated. If necessary, tighten the securing bolt to the specified torque.

The “magic eye” on the battery of your VOLKSWAGEN PASSAT CC 2009 provides information on the electrolyte level and charge state. Before checking, lightly tap the magic eye with a screwdriver handle to dissipate any air bubbles that could distort the display. Note that the display applies only to the single cell it is located in, and a full battery test is needed for an exact condition assessment.

There are two types of colour displays:

“3-Colour” Display (Older batteries):

• Green: Battery is sufficiently charged.

• Black: Battery is partly discharged (charge state < 65%) or completely discharged.

• Colourless or light yellow: Battery must be renewed. DO NOT check, charge, or jump start.

“2-Colour” Display (Newer batteries):

This type only indicates the electrolyte level, not the charge state. A battery load test is required to determine the charge state.

• Black: Electrolyte level is OK.

• Colourless or light yellow: Electrolyte level is too low. The battery must be renewed. DO NOT check, charge, or jump start.

WARNING: In all cases, if the magic eye is colourless or light yellow, the battery must be renewed due to the danger of explosion.

The no-load voltage test is used to assess the battery’s condition on stock and stored vehicles as part of prescribed maintenance. This test determines if the battery requires recharging.

Test Conditions:

The battery must not have been charged or discharged within the last 2 days.

Procedure:

Using a hand multimeter (e.g., V.A.G 1526 B), check the battery’s no-load voltage.

Assessing Results:

Use the following table to determine the necessary action:

A no-load voltage of 11.60 V corresponds to a 0% charge, indicating the battery is heavily discharged and has no capacity.

The functions of the cruise control system (CCS) on your VOLKSWAGEN PASSAT CC 2009 are controlled by the engine control unit. To activate or deactivate the system for diagnostic purposes, you will need a vehicle diagnostic tester.

Follow these steps:

1. Connect the vehicle diagnostic tester to your vehicle.

2. Select “Guided fault finding” mode on the diagnostic tester.

3. Using the “GoTo” button, select “Functions/component” and navigate through the following menu options in sequence:

• Drive

• Engine code

• 01 – On Board Diagnostic capable systems

• Engine management/diesel direct injection and glow plug system

• Functions

• Activating and deactivating cruise control system (CCS)

The tester will then guide you through the activation or deactivation process.

Your VOLKSWAGEN PASSAT CC 2009 uses several types of hose couplings for the windscreen, rear window, and headlight washer systems. Here is how to handle them:

Type 1: Simple Push-Fit (No Securing Device)

• To loosen: Pull the two coupling sections apart.

• To secure: Push the two sections together until you hear and feel them engage.

Type 2: Rotating Lock Ring

• To loosen: Rotate the lock ring 90 degrees and pull off the hose connection.

• To secure: Push on the hose connection and rotate the lock ring back until it engages.

Type 3: Pull-Up Lock Ring/Clip

• To loosen: Pull up the lock ring by approximately 1 mm and pull off the hose connection.

• To secure: Attach the hose connection and press in the clip until it engages.

Type 4: Headlight Washer System Push-Lock Ring

• To loosen: Push the lock ring in the direction of the arrow and pull off the hose connection.

• To secure: Push and hold the lock ring, then push on the hose connection. Check that it is secure by trying to pull it off without depressing the ring.

If a smooth washer pipe (5×1 mm or 6×1 mm) on your VOLKSWAGEN PASSAT CC 2009 is damaged, you can repair it using a special EPDM hose and cable ties.

1. Cut the damaged section out of the smooth pipe, ensuring the cuts are at right angles.

2. Select the appropriate EPDM hose and cable ties from the electronic parts catalogue.

3. Cut the EPDM hose to a length that allows the ends of the smooth pipe to be pushed about 10 mm into each side of the repair hose.

4. Secure the repair joints by fastening a cable tie over each end of the EPDM hose.

Repairing a damaged corrugated washer pipe on your VOLKSWAGEN PASSAT CC 2009 requires special connectors and heat-shrink hose. Ensure that repair points are not subjected to pulling or bending forces.

1. Cut the damaged section out of the corrugated pipe at a right angle.

2. Select suitable end piece connectors and the correct sized heat-shrink piping from the electronic parts catalogue.

3. Use a hot air blower to heat one end of the corrugated pipe.

4. Push a connector into the heated end.

5. Repeat steps 3 and 4 for the other end of the corrugated pipe with the other connector.

6. Cut the heat-shrink hose so that it will cover the ends of the corrugated pipe by about 20 mm on each side of the repair joint.

7. Push the heat-shrink hose over the corrugated pipe, join the connectors, and secure the repair joints by applying heat to the heat-shrink hose until it is sealed.

Gas discharge (xenon) bulbs on your VOLKSWAGEN PASSAT CC 2009 operate under extremely high voltage and pressure. It is critical to follow these safety procedures to avoid serious injury.

High Voltage Danger:

• Control units, connectors, and bulb holder components conduct lethally high voltage.

• Before working on any part of the gas discharge headlight system, you must disconnect the battery earth strap.

• After disconnecting the battery, switch the dipped beam on and off again to eliminate any possible residual voltage in the system.

• Ensure the lights cannot be switched on while you are working.

Physical Hazards:

• Always wear protective goggles and gloves when removing and installing gas discharge bulbs.

• The bulbs are under pressure and can explode if mishandled, causing injury.

• The glass of the bulbs can become very hot, creating a danger of burns.

• Avoid looking directly into the beam. The UV rays are much stronger than those from halogen bulbs, and the intense light can cause glare and temporary vision impairment.

Operational Safety:

• The gas discharge bulb must only be operated inside the headlight housing.

• Never operate the lamp control unit without a gas discharge bulb correctly installed.

• If you are not familiar with the appropriate procedures, do not attempt to change the bulbs.

Gas discharge bulbs from your VOLKSWAGEN PASSAT CC 2009 must be handled and disposed of with care, as they contain hazardous materials.

• Gas discharge bulbs must be disposed of as hazardous waste. Never dispose of them as conventional waste.

• The bulbs contain metallic mercury (Hg) and traces of thallium. Never destroy these bulbs.

• These components must be recycled in accordance with national law.

• Dispose of the bulbs only in containers intended for this purpose at an authorised collection point.

To remove an illuminated cigarette lighter socket from your VOLKSWAGEN PASSAT CC 2009, you need a special puller tool (T 40148). Sockets without illumination usually cannot be removed without being damaged.

CAUTION: Using excessive force can damage the socket or retaining sleeve. The puller tool is designed only for illuminated sockets.

Removal Procedure:

1. If present, remove the cigarette lighter or dummy plug from the socket.

2. Push the puller into the socket so that its locking lugs engage in the recesses inside the socket.

3. Pull the grip of the tool to release the locking lugs of the retaining sleeve.

4. Pull the socket out of the retaining sleeve using the puller. Be careful not to stretch the wiring.

5. If necessary, use the recommended thrust piece (40148/1) with the knurled nut to assist.

6. Pull off the socket connector.

7. To release the puller from the socket, press the spindle on the tool and turn the puller briefly to the left.

To connect a vehicle diagnostic tester to your VOLKSWAGEN PASSAT CC 2009, follow these steps for a safe and correct connection:

1. Apply the handbrake.

2. For vehicles with an automatic gearbox, move the selector lever to position “P” or “N”. For manual gearboxes, move the gearstick to the neutral position.

3. Switch off all electrical consumers.

4. With the ignition switched off, connect the diagnostic tester to the diagnostic interface (OBD port) in the vehicle using the appropriate diagnostic cable (e.g., VAS 5051/6A).

5. Switch on the ignition to power the system and begin communication.

WARNING: During testing, there is a risk of injury if the diagnostic system is placed in the deployment area of an airbag. A triggered airbag can cause serious or fatal injury. It is recommended to work with a second person who can operate the diagnostic system from a back seat.

When performing repairs on the electrical system of your VOLKSWAGEN PASSAT CC 2009, adhere to the following guidelines to ensure safety and quality:

• Disconnect the Battery: Always disconnect the battery earth strap before working on the electrical system to create a safe working environment.

• Identify the Cause: Before starting a repair, identify and rectify the root cause of the damage (e.g., sharp edges, corrosion, defective components).

• No Soldering: Soldering is not permitted for repairs to vehicle wiring. Use approved crimp connectors.

• Use Approved Repair Sets: Wiring harness repairs should be carried out using the specified wiring harness repair set (e.g., VAS 1978 B).

• Mark Repairs: Wiring harness repairs should not be integrated back into the vehicle’s main harness. Mark the repair area with yellow adhesive tape to indicate a previous repair.

• Seal Crimp Connectors: After crimping, connectors must be shrink-fitted using a hot air blower to prevent any ingress of moisture.

• Special Systems: Observe supplementary information for repairs to specific systems like airbags, CAN bus lines, and fibre optic cables.

• Function Test: Carry out a function test after every repair. It may be necessary to interrogate and erase the fault memory.

• Screened Wires: Screened wires must not be repaired. If damaged, they must be replaced completely.

• Heat-Resistant Wiring: In areas like the engine compartment, only use heat-resistant wiring for repairs.

When repairing the CAN bus wiring on your VOLKSWAGEN PASSAT CC 2009, it is crucial to follow specific procedures to maintain signal integrity.

• Wire Type: The CAN bus uses an unshielded, twisted two-wire line with a cross-section of 0.35 mm² or 0.5 mm².

• Twist Spacing: When repairing, both bus wires must be the same length. When twisting the two wires together, the length of each complete twist must be 20 mm.

• Untwisted Length: There must not be any section of wiring longer than 50 mm that is not twisted, especially near crimp connectors.

• Marking: Mark the area of repair with yellow insulation tape for easy identification.

• Colour Codes: The colour codes for the CAN bus wires are as follows:

Releasing and dismantling contact housings on your VOLKSWAGEN PASSAT CC 2009 requires using the correct release tools to avoid damage. Never pull contacts out by force.

1. Disengage Secondary Locking Element:

• Many contact housings have a secondary locking mechanism (housing catch) that secures all wires at once. This is often a different colour from the main housing.

• This secondary lock must be opened or removed before individual contacts can be released.

• Examples of secondary locks include a removable “toothed element,” an opening “flap,” or a detachable “slide.” A small screwdriver can be used as an aid to disengage these.

2. Disengage Primary Locking Element:

• The primary lock is what fixes an individual crimp contact within the housing.

• Insert the appropriate release tool for the specific contact type into the release port of the contact housing.

• Grab the wire of the contact you wish to remove and push it lightly *into* the housing. This action helps lift the locking tabs off the housing edge.

• At the same time, push the release tool further into the housing to fully disengage the contact’s locking tabs.

• Pull the released contact out from the back of the housing.

• Once the contact is removed, the release tool can be pulled out.

Renewing a Lambda probe (LSF 4-pin or LSU 6-pin) on your VOLKSWAGEN PASSAT CC 2009 involves replacing the old probe with a new uniform probe and adapting it to the correct length. Do not attempt to repair Lambda probe wires, as this can result in malfunctions.

General Procedure:

1. Remove the defective Lambda probe from the vehicle.

2. Place the new uniform probe and the old defective probe next to each other, aligning the sensor housings so they are at the same height.

3. Tie back any excess length on the new uniform probe’s cable (typically 50 – 250 mm) to match the length of the old probe’s cable. Secure the excess cable with cable ties.

4. Check that the connector housing of the new Lambda probe is compatible with the connector on the vehicle’s onboard supply side. On newer vehicles, the coding should match. On older vehicles, it may be necessary to replace the vehicle-side connector with the new one supplied with the probe.

5. If replacing the connector, observe the pin assignment carefully. The new connector housing will have colour markings on the pins for clarity.

6. Install the new, correctly sized Lambda probe into the vehicle.

Note: For LSU (6-pin) probes, it is especially critical that the wires are not crimped or cut, as this will impair the function of the probe.