Volkswagen Passat B3

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring With Multi-function indicator, Instrument cluster, assembly: 1990 (Page 90-20-1)

Note See section 90-50 for instrument cluster multi-point connector identification. 1 - Instrument cluster housing removing/installing/disassembly, section 90-30

2 - Hall speed sensor contact plate removing/installing, section 90-80 3 - Speedometer cable cover removing, section 90-70 speedometer cable assembly, section 90-70 4 - Printed circuit removing, section 90-80 5 - Warning lights, right checking, section 90-110 installation position, section 90-100 installing LED, section 90-110 6 - Hall speed sensor located on rear of speedometer 7 - Tachometer with oil pressure warning control unfit removing/installing, section 90-40 connector wiring, section 90-60 8 - Speedometer removing/installing, section 90-40

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Without Multi-function indicator, Instrument cluster, assembly: 1990 (Page 9010-1)

Note See section 90-50 for instrument cluster multi-point connector identification. 1 - Instrument cluster housing removing/installing/disassembly, section 90-30 2 - Hall speed-sensor contact plate removing/installing, section 90-80 3 - Speedometer cable cover removing, section 90-70 speedometer cable assembly, section 90-70 4 - Printed circuit removing, section 90-80 5 - Warning lights, right checking, section 90-110 installation position, section 90-100 installing LED, section 90-110

6 - Tachometer with oil pressure warning control unit removing/installing, section 90-40 connector wiring, section 90-60 7 - Speedometer removing/installing, section 90-40 8 - Instrument cluster cover removing/installing, section 90-30

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Without Multi-function indicator, Instrument cluster, assembly: 1990 (Page 9010-2)

9 - Fuel gauge checking, section 90-120 removing/installing, section 90-40 troubleshooting, section 90-120 10 - Digital clock connector wiring, section 90-60 11 - Coolant temperature gauge and low coolant level Indicator checking, section 90-130 connector wiring, section 90-60 removing/installing, section 90-40 troubleshooting, section 90-130 12 - Voltage stabilizer checking, section 90-90 removing/installing, section 90-90 13 - Hall speed sensor located on rear of speedometer 14 - Warning lights, left checking, section 90-110 installation position, section 90-100 installing LED section 90-110 15 - Bulbs and holders 12 V/1.2 W (watt) checking, section 90-110


Note See section 90-50 for instrument cluster multi-point connector identification. 1 - Instrument cluster housing removing/installing/disassembly, section 90-30

2 - Hall speed sensor contact plate removing/installing, section 90-80 3 - Speedometer cable cover removing, section 90-70 speedometer cable assembly, section 90-70 4 - Printed circuit removing, section 90-80 5 - Warning lights, right checking, section 90-110 installation position, section 90-100 installing LED, section 90-110 6 - Hall speed sensor located on rear of speedometer 7 - Tachometer with oil pressure warning control unfit removing/installing, section 90-40 connector wiring, section 90-60 8 - Speedometer removing/installing, section 90-40


9 - Instrument cluster cover removing/installing, section 90-30 10 - Fuel gauge removing/installing, section 90-40 checking, section 90-120 troubleshooting, section 90-120 11 - Multi-function Indicator (MFI) connector wiring, section 90-280 printed circuit, connector identification, section 90-280 12 - Coolant temperature gauge and low coolant level Indicator checking section 90-130 connector wiring, section 90-60 removing/installing, section 90-40 troubleshooting, section 90-130 13 - Voltage stabilizer checking, section 90-90 removing/installing, section 90-90 14 - Multi-function Indicator (MFI) vacuum sensor removing, section 90-280 15 - Warning lights, left checking, section 90-110 installation position, section 90-100 installing LED, section 90-110 16 - Bulbs and holders 12 V/1.2 W (watt) checking, section 90-110

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Instrument cluster, removing/installing/disassembly: 1990 (Page 90-30-1)

CAUTION! Before working on the electrical system obtain radio security code and disconnect the battery ground strap. Note All components in the instrument cluster (with the exception of conductor foil or printed circuits) can be removed and installed from the front without removing the assembly. Individual components, removing

- Remove trim screws -arrows- and remove trim.

- Remove screws -1-. - Remove (unscrew) trip recorder reset button and pull cover off instrument cluster.

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Instruments, removing/installing: 1990 (Page 90-40-1)

Instrument cluster, removing - Remove horn cover and then steering wheel.

- Remove trim screws -arrows- and remove trim.

- Remove screws -2- left and right. - Pull right side of instrument cluster out from instrument panel. - Disconnect multi-pin plug and MFI pressure sender hose from the rear of housing. (The speedometer cable is pushed in by hand.)

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Instruments, removing/installing: 1990 (Page 90-40-2)

Instruments, removing/installing CAUTION! Before working on any part of the electrical system, disconnect battery ground strap.

1 - Fuel, coolant temperature and low coolant level indicator gauge 2 - Speedometer 3 - Tachometer A - locating pins B - mounting screws

Fuel, coolant temperature and low coolant level indicator gauge squeeze locating pins A on gauge 1 and pull from housing and connector Speedometer remove mounting screws B and pull speedometer 2 from housing Tachometer squeeze locating pins A on tachometer 3 and pull from housing and connector Installing install instruments in reverse order of removal carefully guide plugs on rear of instruments into connectors on printed circuit board.

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Multi-point connector on instrument cluster, identification: 1990 (Page 90-50-1)

Remove fuel, coolant temperature and low coolant level indicator gauge from instrument cluster to access multi-point connector. or Use test box VAG 1598 with adaptor harness 1598/8 for checking and testing. The numbered sockets on test box VAG 1598 correspond to the numbered terminals of the 28point instrument cluster connector. 1 * - ground (-) for outside temperature sensor 2 - not used 3 - ground (-), terminal 31 4 * - to multi-function indicator (MFI) reset switch 5 * - ground (-), terminal 31

6*7 8 9 10 11 12 13 14 15 * 16 17 * 18 19 * 20 21 22 23 24 25 26 27 28 -

to multi-function indicator (MFI) memory switch hall speed sensor signal from oil pressure switch (1.8 bar) from oil pressure switch (0.3 bar) tachometer input signal, terminal 1 plus (+) connection, terminal 30 plus ( + ) connection for instrument lighting, terminal 58b plus (+) connection, terminal 15 not used to multi-function indicator (MFI) mode switch to alternator warning light, terminal 61 from oil temperature sensor to seat belt warning light outside temperature sensor signal not used to fuel gauge on-board diagnosis (OBD) warning light to coolant temperature gauge to turn signal indicator light to high beam indicator light not used not connected not connected

* Vehicles with multi-function indicator (MFI), Canada only

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Instrument cluster, connector wiring: 1990 (Page 90-60-1)

Fuel, coolant temperature and low coolant level indicator gauge 1 - not used 2 - from fuel gauge sender 3 - from coolant temperature sensor 4 - plus (+) connection, terminal 15 5 - not used 6 - not used 7 - ground (-), terminal 31 8 - voltage stabilizer output voltage, 9.5V to 10.5V

Tachometer and oil pressure warning control unit 1 - tachometer input signal, terminal 1 2 - ground (-), terminal 31 3 - to oil pressure warning light 4 - plus (+) connection, terminal 15 5 - tachometer output signal 6 - not used

7 - from oil perssure switch, 1.8 bar 8 - from oil perssure switch, 0.3 bar

Digital clock 1 - MFI plus (+) connection, terminal 15 2 - plus (+) connection for instrument lighting, terminal 58b 3 - plus (+) connection, terminal 30 4 - ground (-), terminal 31

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Speedometer cable and cover, assembly/removing: 1990 (Page 90-70-1)

Speedometer cable, assembly The speedometer cable is pushed into the rear of the instrument cluster and into the speedometer. A spring in the cable housing keeps the cable engaged with the speedometer. A - Instrument cluster with speedometer cable cover B - Speedometer cable 1 - Sealing grommet (plenum chamber to engine compartment) 2 - Spring housing 3 - Sealing grommet (passenger compartment) 4 - Spring housing bracket

Speedometer cable cover, removing turn cover from locked position 1 in direction of arrow to position 2 remove cover from instrument cluster install in reverse order of removal

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Hall speed sensor contact plate and printed circuit, removing and installing: 1990 (Page 90-80-1)

Hall speed sensor contact plate, removing Contact plate presses printed circuit against spring loaded contacts to make connection. remove contact plate mounting screws (arrows) slide contact plate from printed circuit and remove Installing install (keeping flat) printed circuit into contact plate attach printed circuit to retaining lug on contact plate install contact plate (with printed circuit) onto rear of speedometer housing and tighten screws (arrows) Printed circuit, removing/installing remove instrument cluster, section 90-30 remove instruments from instrument cluster housing, section 90-40 remove multi-funtction indicator vacuum sensor (if equipped) remove hall speed sensor contact plate

squeeze spreader pins 1 and carefully remove connector strip with printed circuit CAUTION! DO NOT damage printed circuit when removing push tabs (arrows) in direction indicated and remove multi-point connector plug 2 from housing install in reverse order of removing

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Voltage stabilizer, checking/removing/installing: 1990 (Page 90-90-1)

Checking Check voltage stabilizer when fuel gauge and coolant temperature gauge simultaneously indicate false readings. Leave battery ground strap and multi-point connector on instrument cluster connected for the following tests.

remove instrument cluster trim and cover remove fuel, coolant temperature and low coolant level, indicator gauge 1 by squeezing locating pins A and pulling gauge from housing and connector

connect multimeter US 1119 set to voltmeter scale between positive connection 1 (terminal 15) and ground 2 switch ignition ON must be approximately battery voltage If NO check for open circuit in wiring according to wiring diagram, repair as necessary switch ignition OFF reinstall fuel, coolant temperature and low coolant level indicator gauge

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Voltage stabilizer, checking/removing/installing: 1990 (Page 90-90-2)

remove mounting screws B and remove speedometer 2 from housing

connect multimeter US 1119 set to voltmeter scale between positive connection 1 and ground 2 switch ignition ON must be 9.5V-10.5V If NO replace printed circuit or replace voltage stabilizer Removing CAUTION! Disconnect battery ground strap before working on any part of the electrical system.

The voltage stabilizer is mounted on the instrument cluster housing above the fuel gauge.

remove instrument cluster trim and cover remove fuel, coolant temperature and low coolant level indicator gauge remove mounting screw and slide voltage stabilizer from connector Installing install voltage stabilizer into connector making sure terminals engage connector slots properly tighten mounting screw securely CAUTION! Voltage stabilizer must be tight against housing to ensure proper heat transfer.

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Warning lights, installation position: 1990 (Page 90-100-1)

Left 1 - not used 2 - oil pressure warning light (red), LED 3 - high beam indicator light (blue), bulb 4 - turn signal indicator light (green), LED

Right 1 - seat belt warning light (red), LED 2 - alternator warning light (red), LED 3 - not used 4 - not used

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Warning lights, checking: 1990 (Page 90-110-1)

remove instrument cluster trim and cover remove fuel, coolant temperature and low coolant level indicator gauge 1 by squeezing locating pins A and pulling gauge from housing and connector make all necessary terminal connections at 28-point instrument cluster connector or Use test box VAG 1598 with adaptor harness 1598/8 for checking and testing. Connect adaptor harness 1598/8 to instrument cluster connector only Do not connect 1598/8 to wire harness connector. use a fused external 12V power source to supply. voltage at connector terminals

Oil pressure warning light, red (K3) connect positive (+) supply wire to terminal 13 and negative (-) supply wire to terminal 3 oil pressure warning light must illuminate High beam indicator light, blue (K1) connect positive (+) supply wire to terminal 25 and negative (-) supply wire to terminal 3 high beam indicator light must illuminate Turn signal indicator light, green (K5) connect positive (+) supply wire to terminal 13 and negative (-) supply wire to terminal

24 turn signal indicator light must illuminate

Seat belt warning light, red (K19) connect positive (+) supply wire to terminal 13 and negative (-) supply wire to terminal 18 turn signal indicator light must illuminate Alternator warning light, red (K2) connect positive (+) supply wire to terminal 13 and negative (-) supply wire to terminal 16 alternator warning light must illuminate Instrument cluster illumination (L10) connect positive (+) supply wire to terminal 12 and negative (-) supply wire to terminal 3 instrument cluster lights must illuminate

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Warning lights, checking: 1990 (Page 90-110-2)

If any of the warning lights do not illuminate, check printed circuit for open circuit according to wiring diagram If printed circuit OK replace light emitting diode (LED) or bulb

Light emitting diode (LED) Always check for correct polarity when installing diodes. The minus pole is indicated by: 1 - flat on diode housing 2 - larger pole in diode housing On some diodes, minus pole is also angled.

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Instrument cluster, testing: 1990 (Page 90-115-1)

Note Always refer to appropriate wiring diagram when performing electrical tests. Test conditions battery OK fuses OK disconnect instrument cluster 28-point connector fold down fuse/relay cover for access to fuse/relay panel

Tools required multimeter Fluke 83 (US 1119) test box VAG 1598 with harness adaptor 1598/8 connect to instrument cluster 28-point connector and wiring harness L.E.D. tester US 1115 1 - instrument cluster 2 - test box VAG 1598 3 - adaptor 1598/8 4 - multimeter Fluke 83 (US 1119) 5 - instrument cluster wiring harness


Test step

Item tested

Test condition

Specified value

Cause of problem

1

Power supply and ground (terminals 30 and 31)

switch ignition OFF set multimeter Fluke 83 (US 1119) to volt range and connect between terminals 11 and 3 of test box Must be approx. VAG 1598 12V

If not OK, check wiring for open or short circuits according to wiring diagram, repair as necessary If OK, check printed circuit and connections for open or short circuits, repair/replace as necessary

2

Ignition power supply and ground (terminals 15 and 31)

set multimeter Fluke 83 (US 1119) to volt range and connect between terminals 13 and 3 of test box VAG 1598 Must be approx. switch ignition ON 12V

If not OK check wiring for open or short circuits according to wiring diagram repair as necessary If OK, check printed circuit and connections for open or short circuits, repair/replace as necessary

3

Turn signal indicator light

4

Instrument cluster illumination

connect L.E.D. tester US 1115 between terminals 24 and 3 of test box VAG 1598 switch ignition ON actuate left turn signal

set multimeter Fluke 83 (US 1119) to volt range and connect between terminals 12 and 3 of test box VAG 1598 switch ignition ON switch lights ON

L.E.D. tester must flash

Must be approx. 2.5V to 12V depending on position of instrument panel light dimmer switch (E20)

If not OK, check wiring for open or short circuits according to wiring diagram, repair as necessary If OK, check printed circuit and connections for open or short circuits, repair/replace as necessary If not OK, check wiring for open or short circuits according to wiring diagram, repair as necessary If OK, check printed circuit and connections for open or short circuits, repair/replace as necessary


Test step 5

Item tested High beam indicator light

Test condition set multimeter Fluke 83 (US 1119) to volt range and connect between terminals 25 and 3 of test box VAG 1598 switch ignition ON

Specified value

Must be approx 12V

If not OK, check wiring for open or short circuits according to wiring diagram, repair as necessary If OK check printed circuit and connections for open or short circuits, repair/replace as necessary

Must be approx. 12V


switch high beam headlights ON

6

Alternator light

set multimeter Fluke 83 (US 1119) to volt range and connect between terminals 16 and 3 of test box VAG 1598 start engine

Cause of problem

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Fuel gauge, checking/troubleshooting: All m.y. (Page 90-120-1)

Checking If fuel and Engine Coolant Temperature Gauges simultaneously indicate false readings, check voltage stabilizer, section 90-90. Leave battery and electrical connectors connected for the following tests. check these first: verify complaint battery OK chassis ground OK Fuel Level Sensor ground OK fuse OK

remove wire connector from Fuel Level Sensor connect lead A of VW 1301 to ground connect lead B of VW 1301 to wire (purple/black) leading to fuel gauge

switch ignition ON adjust VW 1301 as follows: Dial setting

Gauge reads

50 160 350

1/1 (full) 1/2 (half) empty (reserve area)

fuel gauge needle must correspond with specified values deviation of one needle width to the left or right is permissible

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Fuel gauge, checking/troubleshooting: All m.y. (Page 90-120-2)

Troubleshooting Use the following procedure to determine the cause of false fuel gauge readings. check fuel gauge (as outlined previously) If fuel gauge checks OK, replace fuel level sensor If fuel gauge needle moves during check, but is inaccurate check voltage stabilizer, section 90-90 output voltage must be 9.5V-10.5V If voltage stabilizer specified value is obtained replace fuel gauge If voltage stabilizer specified value is not obtained replace voltage stabilizer If fuel gauge needle does not move during check check wiring from sensor to gauge according to wiring diagram If wiring is OK, check voltage stabilizer, section 90-90 output voltage must be 9.5V-10.5V If voltage stabilizer checks OK, replace fuel gauge

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Engine Coolant Temperature Gauge, checking/troubleshooting: All m.y. (Page 90-130-1)

Checking If fuel and Engine Coolant Temperature Gauges simultaneously indicate false readings, check voltage stabilizer. Leave battery and electrical connectors connected for the following tests. check these first: verify complaint battery OK chassis ground OK fuse OK

remove connector from Engine Coolant Temperature (ECT) Sensor connect lead A of VW 1301 to ground connect lead B of VW 1301 to wire (yellow/red) leading to Engine Coolant Temperature Gauge

switch ignition ON Engine Coolant Temperature (ECT) warning light 1 flashes for approximately 3 seconds adjust VW 1301 as follows:

Dial setting

Gauge reads

80

engine hot (110 C/230 F)

50

warning zone, engine overheating (warning light 1 flashes)

Engine Coolant Temperature Gauge needle must correspond to specified values deviation of one needle width to the left or right is permissible

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Engine Coolant Temperature Gauge, checking/troubleshooting: All m.y. (Page 90-130-2)

Troubleshooting Use the following procedure to determine the cause of false Engine Coolant Temperature Gauge readings. check Engine Coolant Temperature (ECT) Gauge (as outlined previously) If Engine Coolant Temperature Gauge checks OK, replace Engine Coolant Temperature Sensor If Engine Coolant Temperature Gauge needle moves during check but is inaccurate, check voltage stabilizer, section 90-90 output voltage must be 9.5V-10.5V If voltage stabilizer specified value is obtained replace Engine Coolant Temperature Gauge If voltage stabilizer specified value is not obtained replace voltage stabilizer If Engine Coolant Temperature Gauge needle does not move during check, check wiring from ECT Sensor to ECT gauge according to wiring diagram If wiring checks OK, check voltage stabilizer, section 90-90 output voltage must be 9.5V-10.5V If voltage stabilizer checks OK, replace Engine Coolant Temperature Gauge

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Instrument cluster, assembly, with mechanical speedometer/odometer: From 1991 m.y. (Page 90-140-1)

1 - Instrument cluster trim cover removing, see index 2 - Tachometer (manual transmission only) removing/installing, see index 2A - Tachometer with Transmission Range Selector Lever Display (automatic transmission only) removing/installing, see index 3 - Speedometer removing/installing, see index Vehicle Speed Sensor (VSS), (G 54) removing/installing, see index 4 - Engine Coolant Temperature (ECT) Gauge, Fuel Gauge and digital clock removing/installing, see index 5 - Turn signal Indicator light, right LED installing, see index 6 - Warning lamps, right installation position, see index LED installing, see index

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Instrument cluster, assembly, with mechanical speedometer/odometer: From 1991 m.y. (Page 90-140-2)

7 - Printed circuit with digital clock display and Transmission Range Selector Lever Display vehicles with automatic transmission only replace with instrument duster housing as an assembly only component identification, see index 7A - Printed circuit with digital clock display vehicles with manual transmission only replace with instrument duster housing as an assembly only component identification, see index 8 - Voltage stabilizer with heat sink checking, see index removing/installing, see index 9 - Instrument cluster housing replace with printed circuit as an assembly only 10 - Vehicle Speed Sensor (VSS), (G 54) contact plate removing/installing, see index 11 - Bulbs and holders (black sockets) for lighting digital clock and Transmission Range Selector Lever Display 12V/1.2W removing/installing, see index 12 - Warning lamps, left installation position, see index LED installing, see index 13 - Turn signal Indicator light, left LED installing, see index 14 - Printed circuit for Instrument cluster lighting 15 - Instrument cluster lighting, bulbs and holder (blue sockets) 12V/1.2W 16 - Vehicle Speed Sensor (VSS), (G 54) provides signal for cruise control removing/installing, see index Note As of model year 1993, the Multi-function indicator will be identified in all service information with the new abbreviation MFA. The old abbreviation, MFI, is now used as an emission-related term for Multiport Fuel Injection. This change will only appear on Multi-function indicator information from model year 1993 ; Multi-function indicator information up to model year 1993 will hot change and will continue to use the MFI abbreviation.

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Instrument cluster, assembly, with electronic speedometer/odometer: From 1991 m.y. (Page 90-150-1)

1 - Instrument cluster trim cover removing, see index 2 - Tachometer (manual transmission only) removing/installing, see index 2A - Tachometer with Transmission Range Selector Lever Display (automatic transmission only)

removing/installing, see index 3 - Speedometer (w/ electronic odometer display) removing/installing, see index Vehicle Speed Sensor (VSS), speedometer (G 22), removing/installing, see index 4 - Engine Coolant Temperature (ECT Gauge, Fuel Gauge and Multi-function indicator (MFA) removing/installing, see index 5 - Turn signal indicator light, right LED installing, see index 6 - Warning lamps, right installation position, see index LED installing, see index

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Instrument cluster, assembly, with electronic speedometer/odometer: From 1991 m.y. (Page 90-150-2)

7 - Printed circuit (manual transmission only) replace with instrument cluster housing as an assembly only component identification, see index 7A - Printed circuit with Transmission Range Selector Lever Display (automatic transmission only) replace with instrument cluster housing as an assembly only component identification, see index 8 - Bulbs and holders (black sockets) for lighting Multi-function indicator (MFA), trip odometer and Transmission Range Selector Lever Display 12V/1.2W removing/installing, see index 9 - Instrument cluster housing replace with printed circuit as an assembly only 10 - MFA vacuum sensor removing/installing, see index 11 - Warning lamps, left installation position, see index LED installing, see index 12 - Turn signal Indicator light, left LED installing, see index 13 - Printed circuit for Instrument cluster lighting 14 - Instrument cluster lighting, bulbs and holder (blue sockets) 12V/1.2W Note As of model year 1993, the Multi-function indicator will be identified in all service information with the new abbreviation MFA. The old abbreviation, MFI, is now used as an emission-related term for Multiport Fuel Injection. This change will only appear on Multifunction indicator information from model year 1993 ; Multi-function indicator information up to model year 1,993 will not change and will continue to use the MFI abbreviation.

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Instruments, removing/installing: From 1991 m.y. (Page 90-160-1)

CAUTION! Before working on any part of the electrical system, disconnect battery ground strap. remove-battery ground strap remove instrument cluster trim remove instrument cluster trim cover

For combination fuel gauge, Engine Coolant Temperature Gauge/Engine coolant Level Indicator 1 and tachometer 3 (with or without Transmission Range Selector Lever Display): carefully pull gauge from housing and connector For mechanical speedometer 2: remove mounting screws A and carefully pull speedometer from housing For electronic speedometer (with electronic odometer display) 2: carefully pull speedometer from housing and locating pins A install instruments in reverse order of removal CAUTION! DO NOT damage printed circuit when installin the instruments. carefully guide plugs on rear of instruments into connector on printed circuit board

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Multi-point connector on instrument cluster, identification: From 1991 m.y. (Page 90-170-1)

Note Use test box VAG 1598 with adaptor harness 1598/8 for checking and testing. The numbered sockets on test box VAG 1598 correspond to the numbered terminals of the 28point instrument cluster connector. 1 - ground (-) for outside temperature sensor (MFA) 2 - to Engine Coolant Level (ECL) Sensor 3 - ground (-), terminal 31 4 - to Multi-function Indicator (MFA) memory switch (reset) 5 - ground (-), terminal 31 6 - to MFA memory switch (memory) 7 - signal from Vehicle Speed Sensor (VSS), (G 54), with mechanical speedometer/odometer signal from Vehicle Speed Sensor (VSS), speedometer, (G 22), electronic speedometer (G 21) output, with electronic speedometer/odometer 8 - from oil pressure switch (1.8 or 1.4 bar) 9 - from oil pressure switch (0.3 bar) 10 - tachometer input signal, terminal 1/terminal W 11 - plus (B+) connection, terminal 30 12 - plus (B+) connection for instrument lighting, terminal 58b 13 - plus (B+) connection, terminal 15 14 - not used 15 - to MFA mode switch 16 - to Generator warning light, terminal 61 17 - from oil temperature sensor (for MFA) 18 - to seat belt warning light 19 - outside temperature sensor signal (for MFA) 20 - not used

21 - to fuel gauge 22 - to turn signal indicator light, left 23 - Engine Coolant Temperature (ECT) Sensor (to gauge) 24 - to turn signal indicator light, right 25 - to high beam indicator light 26 - not used 27 - speed signal from Vehicle Speed Sensor (VSS), speedometer (G 22), with electronic speedometer/odometer 28 - Transmission Range Selector Lever Display (automatic transmission only)

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Warning lights (left and right), installation position: From 1991 m.y. (Page 90180-1)

Left 1 - Warning light (red) for Engine Coolant Temperature (ECT)/Engine Coolant Level (ECL), LED 2 - not used 3 - oil pressure warning light (red), LED 4 - high beam indicator light (blue), bulb

Right 1 - seat belt warning light (red), LED 2 - Generator warning light (red), LED 3 - not used 4 - not used

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Light emitting diode (LED) and turn signal indicator lights, installing: From 1991 m.y. (Page 90-190-1)

Light emitting diode (LED), installing Always check for correct polarity when installing diodes. The minus (-) pole is indicated by: 1 - flat on diode housing 2 - larger pole in diode housing On some diodes, minus (-) pole is also angled

Turn signal indicator lights, installing install LED's as shown 1 - LED 2 - upper light socket (with clip) 3 - lower light socket

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Warning lights, removing/installing: From 1991 m.y. (Page 90-200-1)

Removing

unclip and remove upper half of light base (socket) pull out and remove LED Installing install in reverse order or removal proper installation position of LED is marked on top ledge of lower light base (socket)

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Instrument cluster lights, identification/removing/installing: From 1991 m.y. (Page 90-210-1)

Identification 1 - bulb for Transmission Range Selector Lever Display (automatic transmission only) 2 - bulb for electronic odometer display 3 - bulb for Multi-function indicator (MFA) display or digital clock

Removing/installing Removing turn slot 1 vertical to unlocked position remove bulb Installing insert bulb turn slot 1 horizontal to locked position

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Voltage stabilizer, checking: From 1991 m.y. (Page 90-220-1)

Vehicles with mechanical speedometer/odometer only Check voltage stabilizer when fuel gauge and Engine Coolant Temperature (ECT) Gauge simultaneously indicate false readings. Leave battery ground strap and multi-point connector on instrument cluster connected for the following tests. remove instrument cluster trim remove tachometer by carefully pulling from printed circuit board

set multimeter Fluke 83 (US 1119) to voltmeter scale and connect between plus (+) connection a (terminal 15) and ground (-) b switch ignition ON approximately battery voltage If NO check wiring according to wiring diagram, repair as necessary switch ignition OFF connect multimeter Fluke 83 (US 1119) between plus (+) connection c and ground ()b switch ignition ON must be 9.5-10.5 V If NO replace voltage stabilizer

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Voltage stabilizer, removing/installing: From 1991 m.y. (Page 90-230-1)

Vehicles with mechanical speedometer/odometer only The voltage stabilizer is located on the instrument panel printed circuit board, behind the tachometer. Removing CAUTION! Before working on any part of the electrical system, disconnect battery ground strap.

remove instrument cluster trim remove tachometer by carefully pulling from printed circuit board remove mounting screw 2 from heat sink 3 slide voltage stabilizer 1 from connector Installing install voltage stabilizer into connector making sure terminals engage connector slots properly install and tighten mounting screw securely CAUTION! Voltage stabilizer must be tight against heat sink 3 to ensure proper heat transfer.

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Voltage stabilizer, checking: From 1991 m.y. (Page 90-240-1)

Vehicles with electronic speedometer/odometer only Check voltage stabilizer when fuel gauge and Engine Coolant Temperature (ECT) Gauge simultaneously indicate false readings. Leave battery ground strap and multi-point connector on instrument cluster connected for the following tests. remove instrument cluster trim remove tachometer by carefully pulling from printed circuit board

set multimeter Fluke 83 (US 1119) to voltmeter scale and connect between plus (+) connection a (terminal 15) and ground (-) b switch ignition ON approximately battery voltage If NO check wiring according to wiring diagram, repair as necessary switch ignition OFF connect multimeter Fluke 83 (US 1119) between plus (+) connection c and ground (-) b switch ignition ON must be 9.5-10.5 V If NO replace instrument cluster printed circuit and housing Note The voltage stabilizer cannot be replaced separately. If the voltage stabilizer is faulty, the entire instrument cluster printed circuit and housing must be replaced.

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Printed circuit, component identification: From 1991 m.y. (Page 90-250-1)

Vehicles with mechanical speedometer/odometer only

Front 1 - printed circuit 2 - turn signal indicator lights, left/right 3 - voltage stabilizer with heat sink 4 - Transmission Range Selector Lever (automatic transmission only) 5 - warning lights, right 6 - warning lights, left 7 - digital clock replace with printed circuit and housing as an assembly only

Rear 1 - dynamic oil pressure warning buzzer replace with printed circuit and housing as an assembly only 2 - printed circuit 3 - 28-point connector to wiring harness 4 - digital clock illumination 5 - Transmission Range Selector Lever Display illumination (automatic transmission only)

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Printed circuit, component identification: From 1991 m.y. (Page 90-260-1)

Vehicles with electronic speedometer/odometer only

Front 1 - printed circuit 2 - printed circuit for instrument-lighting 3 - turn signal indicator lights, left/right 4 - Transmission Range Selector Lever Display (automatic transmission only) replace with printed circuit and housing as an assembly only 5 - warning lights, right 6 - electronic odometer display replace with printed circuit and housing as an assembly only 7 - warning lights, left 8 - Multi-function indicator (MFA) replace with printed circuit and housing as an assembly only

Rear 1 - voltage stabilizer replace with printed circuit and housing as an assembly only 2 - dynamic oil pressure warning buzzer 3 - printed circuit for instrument lighting 4 - printed circuit plug connector 5 - 28-point connector to wiring harness

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Vehicle Speed Sensor (VSS) (G 54), removing/installing: From 1991 m.y. (Page 90-2701)

Vehicles with mechanical speedometer/odometer only CAUTION! Before working on any part of the electrical system, disconnect battery ground strap.

Removing remove instrument cluster trim remove speedometer mounting screws and carefully pull speedometer from housing remove contact plate mounting screws 3 remove contact plate 1 and spring contacts 2 remove Vehicle Speed Sensor (VSS), (G 54) Installing install in reverse order of removal

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring MFA vacuum sensor and Vehicle Speed Sensor (VSS), speedometer (G 22), removing/installing: From 1991 m.y. (Page 90-280-1)

Vehicles with electronic speedometer/odometer only

MFA vacuum sensor Removing remove instrument cluster remove vacuum hose from connector 2 remove screws 3 remove vacuum sensor 1 from instrument cluster Installing install in reverse order of removal

Vehicle Speed Sensor (VSS), speedometer (G 22) The Vehicle Speed Sensor (VSS), speedometer (G 22) is mounted on the transmission. Removing remove wire connector loosen sensor using a 22 mm wrench remove VSS (G 22) Installing install in reverse order of removal Note As of model year 1993, the Multi-function indicator will be identified in all service information with the new abbreviation MFA. The old abbreviation, MFI, is now used as an emission-related term for Multiport Fuel Injection. This change will only appear on Multi-function indicator information

from model year 1993; Multi-function indicator information up to model year 1993 will not change and will continue to use the MFI abbreviation.

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Instrument cluster, testing: From 1991 m.y. (Page 90-290-1)

Note Always refer to appropriate wiring diagram when performing electrical tests. Test conditions battery OK fuses OK disconnect instrument cluster 28-point connector fold down fuse/relay cover for access to fuse/relay panel

Tools required multimeter Fluke 83 (US 1119) test box VAG 1598 with harness adaptor 1598/8 connect to instrument cluster 28-point connector and wiring harness LED tester US 1115 1 - instrument cluster 2 - test box VAG 1598 3 - harness adaptor 1598/8 4 - multimeter Fluke 83 (US 1119) 5 - instrument cluster wiring harness (28-point connector)


Test step 1

2

Item tested

Test condition

Power supply and ground (terminals 30 and 31)

switch ignition OFF

Ignition power supply and ground (terminals 15 and 31)

set multimeter Fluke 83 (US 1119) to volt range and connect between terminals 11 and 3 of test box VAG 1598

set multimeter Fluke 83 (US 1119) to volt range and connect between terminals 13 and 3 of test box VAG 1598 switch ignition ON

3

Turn signal indicator light

Specified value

Must be approx. 12V


Must be approx. 12V

If not OK check wiring for open or short circuits according to wiring diagram repair as necessary If OK, check printed circuit and connections for open or short circuits, repair/replace as necessary



connect L.E.D. tester US 1115 between terminals 22 and 3 of test box VAG 1598 switch ignition ON actuate left turn signal

Cause of problem


Test step 4

Item tested Turn signal, right

Test condition

actuate right turn signal

Instrument cluster/digital display illumination

set multimeter Fluke 83 (US 1119) to volt range and connect between terminals 12 and 3 of test box VAG 1598 switch ignition ON switch lights ON

6

High beam indicator light

Cause of problem



connect L.E.D. tester US 1115 between terminals 24 and 3 of test box VAG 1598 switch ignition ON

5

Specified value

set multimeter Fluke 83 (US 1119) to volt range and connect between terminals 25 and 3 of test box VAG 1598 switch ignition ON

Must be approx. If not OK, 2.5V to 12V check wiring for open depending on or short circuits position of according to wiring instrument panel diagram, repair as light dimmer switch necessary (E20) If OK, check printed circuit and connections for open or short circuits, repair/replace as necessary

Must be approx 12V

If not OK, check wiring for open or short circuits according to wiring diagram, repair as necessary If OK check printed circuit and connections for open or short circuits, repair/replace as necessary

Must be approx. 12V


switch high beam headlights ON

7

Generator light

set multimeter Fluke 83 (US 1119) to volt range and connect between terminals 16 and 3 of test box VAG 1598 start engine

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring Anti-theft alarm system, general information: From 1991 m.y. (Page 90-300-1)

The anti-theft alarm system has two types of alarms, visual and audible. If the alarm system is activated (vehicle broken into) the emergency flashers will flash, the alarm horn will sound and the starter will be deactivated. The alarm system monitors and protects the following: engine compartment (hood) luggage compartment (trunk lid) doors ignition (starter lock-out) The alarm system has a self-diagnostic feature which checks the operation of its components and wiring. When the alarm system is armed and all components are functional, the alarm horn will sound briefly after either front door is locked with the key. The alarm system can only be armed when the hood, trunk lid and all doors are closed.

Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring 1991-1992 m.y., Anti-theft alarm system, troubleshooting: 1991 - 1992 m.y. (Page 90310-1)

Tools required

use digital multimeter Fluke 83 (US 1119) for all electrical tests

use connector test kit VW 1594 for all electrical test connections refer to wiring diagram at end of this section when troubleshooting


Alarm system cannot be switched ON (alarm horn does not beep when either front door is locked with key) Test conditions battery OK power window and central locking system circuit breaker (S52, 20A) OK (located above fuse/relay panel) hood closed doors closed trunk lid closed before disconnecting battery ground strap, obtain radio security code







Alarm system cannot be switched OFF Test conditions anti-theft alarm system is switched ON battery OK obtain radio security code before disconnecting battery ground strap


Lights flash but alarm horn does not sound when alarm is activated Test conditions anti-theft alarm system is switched ON battery OK obtain radio security code before disconnecting battery ground strap


Alarm horn sounds but lights do not flash when alarm is activated Test conditions anti-theft alarm system is switched ON battery OK emergency flasher system OK obtain radio security code before disconnecting battery ground strap


Engine does not crank with alarm system OFF Test conditions anti-theft alarm system switched OFF battery OK obtain radio security code before disconnecting battery ground strap


Description

Current track

Alarm horn, H8

1

Alarm switch, hood. F120

2

Alarm switch, trunk lock, F124

15

Alarm trunk latch/luggage compartment light switch, F5

19

Anti-theft alarm system control unit J284

1-25

Fuel pump relay, J17

3

Wire connectors T1 - single, behind fuse relay panel T1a - single, behind fuse relay panel T1b - single, below rear seat bench T1c - single, below rear seat bench T1d - single, in luggage compartment left T1e - single, in luggage compartment left T1f - single, in luggage compartment, left T1g - single, in rear lid T1h - single, in luggage compartment, left T2 - double, below rear seat bench T2a - double, behind fuse relay panel T2b - double, behind fuse/relay panel T3j - three-point, on left front turn signal T3k - three-point, on right front turn signal T4 - four-point, behind ,fuse relay panel T6 - six-point,on anti-theft alarm system control unit T6a - six-point, in rear lid T10 - ten-point, on anti-theft alarm system control unit T28 - twenty eight-point, on instrument cluster T36 - wire junction terminal 30 behind fuse relay panel Ground connections 30 - beside fuse relay panel 98 - in rear lid wiring harness 106 - in anti-theft alarm system wiring harness Welded wiring harness points C15 - wire connection, in headlight wiring harness C16 - wire connection, in headlight wiring harness Q51 - plus (+) connection (30) in-anti-theft alarm system wiring harness Q52 - wire connection, (door contact switch), in anti-theft alarm system wiring harness

Q53 Q54 Q55 S3 S5 -

plus connection (15) in anti-theft alarm system wiring barness wire connection (left turn signal), in anti-theft alarm system wiring harness wire connection (right turn signal), in anti-theft alarm system wiring harness wire connection, in central locking system wiring harness wire connection, in central locking system wiring harness



Volkswagen B3 Passat Radio-Wipers-Lights-Switches-Wiring From 1993 m.y., Anti-theft alarm system, troubleshooting: From 1993 m.y. (Page 90320-1)

Tools required use digital multimeter Fluke 83 (US 1119) for all electrical tests

use connector test kit VW 1594 for all electrical test connections refer to appropriate wiring diagram when troubleshooting


A - Anti-theft alarm system cannot be switched on Alarm system indicator light does not light up (from August, 1992 ) Test conditions: Trunk lid/hatch closed and locked Doors closed Hood closed Battery voltage OK Power window and central locking system fuses OK Fuses S90 and S91 OK




B - Anti-theft alarm system cannot be switched off Test conditions: Anti-theft alarm system switched on Battery voltage OK


C - Activated anti-theft alarm system does not trigger alarm horn Test conditions: Anti-theft alarm system activated Battery voltage OK


D - Activated anti-theft alarm system does not trigger flasher lights Test conditions: Anti-theft alarm system activated Battery voltage OK Emergency flasher system OK


E - Starter does not crank with anti-theft alarm system switched off Test conditions: Anti-theft alarm system switched off Battery voltage OK