General instructions for repairing car electrical systems (VW Passat B6)

Attention: When disconnecting and connecting the battery, be sure to follow the sequence of actions described in the repair manual.

Caution: Some tools have a safety loop that should be placed on the working part of the tool after use to protect the tool from damage and the worker from injury.

For any repairs, please observe the current instructions in the relevant repair manuals.

Follow the rules in force in the country.

Before working with electrical equipment, disconnect the ground wire from the battery.

Unscrew the ground wire from the battery (cessation of current in a circuit), make work on electrical equipment safe. The positive terminal should only be unscrewed to remove the battery.

Before starting repairs, it is necessary to first eliminate the cause of the damage, for example, body parts with sharp edges, a faulty electrical consumer, corrosion.

When repairing the on-board electrical system wiring, welding work is prohibited.

Repairs to the wiring and plugs of the on-board network may only be carried out using a cable repair kit.

When repairing cables, use only yellow wires.

Repaired areas of wires must not be re-wrapped with standard automotive electrical tape; these areas must be marked with yellow electrical tape.

Yellow wires and areas marked with yellow electrical tape indicate that repairs have been made there previously.

Crimping sleeves must not be repaired. If possible, run a new wire parallel to the damaged one.

After crimping, the crimping sleeve must be seated to prevent moisture from getting inside it.



Be sure to follow the additional instructions for repairing wiring in the airbag and seat belt tensioner systems, fibre optic cables, CAN bus cables, antenna cables and cables with a cross-section of up to 0.35 mm².

After each repair, it is necessary to test the operation of the repaired element. If necessary, it is necessary to read the fault memory, clear it and/or return the system to its original position.

If possible, do not unscrew the ground wires from the body (danger of corrosion).

Repair of wires in airbag and seat belt tensioner systems

In addition to general wiring repairs, the following guidelines must be followed when repairing wiring in the airbag and seat belt pretensioner systems:

Caution: The airbag and seat belt pretensioner systems may be damaged.

Caution: Failure to follow the instructions when repairing the pretensioner and airbag wiring harnesses may result in failure of these passive safety systems.

Caution: When repairing airbag and seat belt tensioner wires, only use designated contacts, plugs and wires.

Note: Airbag and seat belt tensioner wires may only be repaired using a cable repair kit.

Note: Follow the instructions on the stickers on the vehicle parts regarding high-voltage components. Residual pressure must be released during repair work.

The airbag or seat belt tensioner wire may be repaired in no more than two places (fig. 7.124).

Places where repairs have been carried out increase electrical resistance and can thus cause failures in the system's self-diagnosis.

When repairing the airbag module and seat belt pretensioner wiring harnesses, the crimp connectors must be seated to prevent corrosion.

When repairing cables, use only yellow wires.

Do not wrap the repaired area with standard electrical tape, but mark it with yellow electrical tape.



The repaired area in the airbag and seat belt tensioner area must be no further than 30 cm from the next connector housing (fig. 7.125).

Together with the yellow insulating tape marking, this provides an easy overview of the repair work carried out.

Wires to pyropatrons (airbags) in serial production, they have a twist with a pitch of 20 mm ±5. Such a twist pitch is designated in serial production by the numbers of standard parts for pairs of wires, therefore, when repairing, it is necessary to observe the pitch of the twisted wires.



When repairing the wire to the pyropatrons (airbags) must be of the same length. When twisting wires 1 and 2, the twist pitch A=20 mm ±must be maintained (fig. 7.126).

In this case, a section of wire should not be formed, for example, in the area of the weld contacts longer than B=100 mm without twisting the wires.