Removal and installation the junction box in the left side of the engine compartment (VW Passat B6)

Contents: Removal ↓ Installation ↓

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

Removal

Disconnect the battery.

Fig. 7.112. Switching unit cover

Install the safety clip 1 in the direction of the arrow and remove the cover of the switching unit 2 upwards (fig. 7.112).

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Fig. 7.113. Hex nuts

Unscrew the hex nuts 1 (fig. 7.113).

Open the covers of the 2 cable guides on the junction box.

Remove the cables from the connecting bolts.

Unlock the cables from the guides.

Unscrew the central bolt of the switching block 1.

Fig. 7.114. Switching block

Note: When unscrewing the central bolt, the switching unit 1 will be pressed upwards from the switching unit holder (fig. 7.114).

Remove the switch unit 1 from the holder upwards.

Fig. 7.115. Housing with surface contacts

Note: To remove the housing with surface contacts 1, it is necessary to remove the air filter housing (only for vehicles with diesel engines) and battery holder (fig. 7.115).

If necessary, remove the air filter housing.

Remove the battery.

Fig. 7.116. Battery holder mounting bolts

Unscrew the battery holder mounting bolts 1 (fig. 7.116).

Remove battery holder 1 from the vehicle.

Release the tabs on the holder of the switching block B and remove the housing with surface contacts, moving the housing 1 to the side A, from the holder of the switching block (fig. 7.115).

Release the tabs on the holder of the switching block C and remove the housing with surface contacts, moving the housing 2 forward D, from the holder of the switching block.

Fig. 7.117. Fastening nuts of the switch block holder

Unscrew the fastening nuts of the switch unit holder 1 (fig. 7.117).

Note: The presence of an additional relay block depends on the vehicle configuration.

Remove the holder of the switching unit 1 as far as the length of the cables of the additional relay unit allows.

Unlock the additional relay block 1 sideways from the switch block holder (fig. 7.117).

Remove the junction box holder 2 from the vehicle.

Installation

Installation is carried out in the reverse order, taking into account the following.

Tighten the mounting bolts and nuts to the specified torque.

Install cover 2 on the switch unit and move safety clip 1 in the direction of the arrow until cover 2 locks into place (fig. 7.112).