Volkswagen Passat 2006 Manual

Service Training
Self-study programme 339
The Passat 2006

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The self-study programme portrays the design
and function of new developments!
The contents will not be updated.
For current testing, adjustment and repair
instructions, please refer to the customer
service literature intended for this purpose.
●Uncompromising safety
●Generous amount of space and variability
●High level of economy
●All-encompassing comfort
●Characteristic design and product aesthetics
●Excellent quality
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The Passat – the unique comfort experience
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:
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

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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
At a glance

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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.
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Emden
Zwickau
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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
rolled off the assembly line in Zwickau/Mosel.
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In brief
The Passat 2006
The Passat 2006 will point the way forward in many
disciplines, e.g.
- Design
- Vehicle dynamics
- Drive technology
- Spatial availability
- Safety
- Quality
●Dual-zone Climatronic
●Light assist
●Transversely mounted engine
●Bluetooth premium mobile
phone pre-installation
●Cornering light system
with bi-xenon
●Adaptive Cruise Control
●Comfortable key concept

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●Tyre pressure monitor systems
●Electromechanical parking brake
●Rear lights with LED technology
●Boot lid easy opening
●230V socket
●High-end sound system
●Multi-link rear suspension

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In brief
Length 4765 mm
Width 1820 mm
Height 1472 mm
Wheelbase 2709 mm
Roof load 100 kg
Trailed load (braked) 1300 kg
Front track 1552 mm
Rear track 1551 mm
Permissible gross vehicle weight 1950 kg
Unladen weight without driver 1391 kg
Drag coefficient 0.281 cd
Fuel tank capacity 70 litres
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Technical data
Passat saloon 2006

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Interior dimensions
1 Headroom, front 973 mm
2 Headroom, rear 961 mm
3 Interior length 1797 mm
4 Luggage compartment volume 565 litres*
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* Including 80 litres in the spare wheel
recess storage space

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Body
The following assemblies are manufactured from
ultra-high-strength steel panels:
●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
●The B-pillar
The body structure
The new Passat's body has been optimised in terms of
the following focal points:
●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.
Cross members in the footwell area
A-pillar
Front bumper cross member
Centre tunnel
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What are ultra-high-strength, hot-formed steel
panels?
These are steel panels which, as the name implies, are
formed when hot at temperatures of between 900 °C
and 950 °C.
The steel panels are provided with their high strength
thanks to a specific cooling process in the forming die.
They are form-hardened.
The use of ultra-high-strength, hot-formed steel
panels has enabled the body weight to be lowered by
approx. 20 kg without reducing the strength.
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Yield strengths of the steel panels which are used:
●Steel panels up to 140 MPa
●High-strength steel panels from 180 to 240 MPa
●Higher-strength steel panels from 260 to 300 MPa
●Ultra-high-strength steel panels from 300 to
420 MPa
●Ultra-high-strength, hot-formed steel panels
over 1000 MPa
1 MPa = 1 Newton/mm2
Ultra-high-strength 300 - 420 MPa
Ultra-high-strength, hot-formed > 1000 MPa
Steel panels < 140 MPa
High-strength 180 - 240 MPa
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B-pillar
Roof frame
Centre tunnel
Inner sills
Outer sills
Longitudinal member
Higher-strength 260 - 300 MPa
Seat brackets

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Spot weld bonds
●in the area of the longitudinal member to the floor
panel
●in the area of the lower sill
●in the area of the rear wheel housing
Laser soldered joints
●in the roof skin
●side panel/luggage compartment sealing duct
Body
The following joining techniques
are employed:
Laser welds
●in the area of the door apertures
●on the front and rear roof member
●on the lateral windscreen frame
●in the area of the front wheel housing
●in the area of the lower rear window frame
●on the rear cross panel
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.
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Spot welding and bonding
Laser welding

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In the event of a lateral crash, the passenger survival
space is ensured by means of a triple-shell side wall.
This is supported on the underlying body structure.
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.
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.
The body colours correspond to the
assignment of the steel panel grades
from the body structure depiction.
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View from below
Side view
orces from
frontal crash

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Body
The seats
The front seats
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.
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Head restraint adjustment is carried out
via an integrated actuation mechanism.
Seat rails
4-way lumbar support

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

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Body
The backrest locking mechanism
The backrests are locked by means of a rotary latch
lock.
If the backrest is not locked, this is displayed via a red
indicator.
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Rotary latch lock
Body bow
Indicator
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The rear seats
The rear seat bench is split 1/3 to 2/3.
The seat backrests can be individually folded.

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The integrated child seats
A rear seat bench with two integrated child seats is
optionally available.
The seat cushions on the outer seats can be raised.
This serves to raise the seat for small children.
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Seat cushion not raised
Seat cushion raised
Footrest
Handle for raising
Raising mechanism
Lateral bolsters,
can be folded up
After raising the seat cushion, the lateral bolsters have
to be raised manually. On folding down, these
automatically return to their original position.

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Lock cylinder not clamped … Lock cylinder clamped …
Body
The door lock
The door locks are actuated by means of a Bowden cable between the door handle and the door lock.
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.
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Bowden
cable
Bolt
Lever
Lever fulcrum
Lever fulcrum
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Lever Lever
Lock actuation
mechanism
Lock actuation
mechanism
Door lock
Aperture for
lock cylinder
Bolt Bolt

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The rear window roller blind
The rear window roller blind is available as either a
mechanical or an electric version.
●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
centre console.
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.
In its upper terminal position, the drive motor is
deactivated via an electronic force limiter. This
prevents body parts from becoming trapped between
the rear window roller blind and the surrounding trim
components.
Guide
Rear window roller blind,
lower terminal position
Guide slot
Guides for Bowden cables
Drive motor S339_134
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Button
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Rear window roller
blind, upper terminal
position
Pressing the button again causes the rear window
roller blind to retract into the rear shelf. It is integrated
flush into the rear shelf.
Rear window roller blind,
upper terminal position
Sliding block in the guide
(not visible)

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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
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.
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Early crash sensor