Wednesday, November 23, 2011

How to replace the G62 Coolant Sensor on a 2006 VW Passat 2.0T

VW Passat G62 Coolant Sensor.

The CEL (Check Engine LIght) came ON and after scanning the car with VAG-COM by Ross-Tech, the report displayed the following fault code:

008577 - Performance Malfunction in Cooling System
P2181 - 008 - Implausible Signal - MIL ON
Freeze Frame:
Fault Status: 11101000
Fault Priority: 0
Fault Frequency: 2
Mileage: 84971 km
Time Indication: 0
Date: 2011.09.24
Time: 16:47:51

Freeze Frame:
RPM: 1491 /min
Load: 27.4 %
Speed: 52.0 km/h
Temperature: 74.0°C
Temperature: 42.0°C
Absolute Pres.: 1000.0 mbar
Voltage: 14.097 V

This fault code could result from various causes. These causes could range from a faulty thermostat, G62 Coolant Sensor, radiator fan, or even a discrepancy in the antifreeze concentration. In my case, it was a faulty G62 Sensor.


First of all, the G62 Coolant Sensor is located on the right side of the engine at about mid level. It is a black plug in the middle of the image below with a green and brown wire attached to it.

This is a close up of the G62 Coolant Sensor Plug.


Remove the black G62 Coolant Sensor plug. After that, you must remove the fastening clip in the 2nd image below. This clip slides into a groove that is perpendicular to the G62 Coolant Sensor, and holds it in place. It prevents the G62 Coolant Sensor from popping out and leaking all the antifreeze. You can see the groove in the 1st picture below, on the top part of the black part where the sensor plugs into.


Now, there is an easy way to replace the G62 Coolant Sensor without flushing out all the antifreeze. You put a few folded towels under the sensor, pull out the old sensor and insert the new G62 Coolant Sensor. Before doing this, make sure that the new sensor is ready with a new O Ring on it. When you pull the old sensor out, antifreeze is going to start leaking out, but it only takes a few seconds to plug in the new sensor and stop the leak. ***One problem that might arise when you pull out the old G62 Coolant Sensor is that the O ring may slide off the sensor, so you have to stick your finger in the opening and pull it out.*** So make sure that the engine is cold so you don't burn yourself with hot antifreeze.***


After inserting the new G62 Coolant Sensor, place the fastening clip into its groove and make sure the sensor can't be pulled out. Then insert the plug back into the G62 Coolant sensor until it clicks into a fastened position.

Step 5

Finally, check the level of antifreeze and add coolant accordingly to adjust for the loss during the replacement of the G62 Coolant Sensor. Scan the car with VAG-COM again and clear the fault code. Then start the engine and check for any leaks.

Sunday, November 20, 2011

How to replace the Steering Wheel Clockspring on a 2006 VW Passat 2.0T (Part 1).

VW Passat 2.0T Steering Wheel Clockspring.

While making a turn at an intersection, the airbag light came ON in the dash and then the MFD (multifunction display) showed Airbag Fault. Also, the buttons on the steering wheel stopped working and wouldn’t even light up when the headlight switch was turned to the ON position. I scanned the car with VAG-COM by Ross-Tech and the following fault codes showed on the report.

01587 - Igniter 2 for Airbag; Drivers Side (N250)
001 - Upper Limit Exceeded - Intermittent - MIL ON
00588 - Airbag Igniter; Driver Side (N95)
001 - Upper Limit Exceeded - Intermittent - MIL ON

Due to the fact that the steering wheel multifunction buttons stopped working and lighting at the same time as the airbag fault light came ON, it narrowed it down to the steering wheel Clockspring. Below are step by step illustrations showing how to replace the steering wheel clockspring on a 2006 VW Passat 2.0T.


First of all, you need to start by placing the key in the ignition and pressing it in until the dash icons light up only without starting the engine. Making sure that the steering wheel is in the center position, turn the steering wheel 90 degrees to the left. Now leave the key/steering wheel in this position, and disconnect the battery cables. After disconnecting the battery, don’t start working on the car for about 20 minutes to make sure all circuits are off. Otherwise, there is a chance that the airbag may deploy when it is being disconnected. Now the reason why we left the key in the ignition is to avoid the steering wheel from locking up when we turn it with the battery disconnected.


Now, start by prying open the top cover of the steering wheel with a flat head screwdriver and cloth to avoid scratching the plastic. It pops right off because it is held on by clips. After you remove this cover you will be able to see the steering wheel clockspring right behind the steering wheel and it will make the steering wheel clips easier to access.

This is the steering wheel Clockspring from a vertical view. It is the first part right behind the steering wheel with a white rectangular sticker on it.

Place a small mirror on the dash so you can get a rear view of the steering wheel. You will see the metal steering wheel clips that hold the steering wheel airbag.

Place a small screw driver on top of the metal clip and press it down to release it from the black latch. After doing so, the steering wheel airbag will come loose and pop out from one side. After releasing the first airbag clip, turn the steering wheel 180 degrees so the second airbag clip is in the vertical position and release it as well. Now the steering wheel airbag should be full detached and only connected by the yellow wire harness.

Now the yellow airbag connecter harness has an organge part on the right side. Inorder to disconnect it, you need to slide the orange part toward you in an upward dirction and it will detach.

Now turn the steering wheel back to the center position. Pay special attention if there are two markings 1)on the top edge of the center shaft and 2)on the opposite side of the first marking on the steering wheel part is your second marking. When you remove the steering wheel and want to put it back, these two markings have to be aligned inorder for the steering wheel to be centered. It should have these markings already, but if it doesn't, then mark them before removing the steering wheel.

Remove the center bolt that attaches the steering wheel.

This is a close up of the markings mentioned in the earlier step. Make sure they are there before removing the steering wheel.

Unscrew the two screws on the sides of the Clockspring to remove the lower steering column cover.

Beneath the Clockspring is the electronic module (with the yellow sticker on it), which the Clockspring plugs into.

On the right side of the electronic module are two black plastic clips. You need to unlatch them with a small flathead screwdriver to release the electronic module below, causing it to drop and detach from where the Clockspring is plugged into it on the front right side (where the yellow sticker is in the 2nd picture).

Now, remove the steering wheel Clockspring by simply pulling it out.

How to replace the Steering Wheel Clockspring on a 2006 VW Passat 2.0T (Part 2).


Now, pay special attention to the red safety cover on the steering wheel Clockspring. It's purpose is to keep the Clockspring in a center position until it is installed. Place the steering wheel Clockspring into position.

After you have placed the steering wheel Clockspring into position, remove the red safety cover and make sure you don't turn the Clockspring at all until final assembly of the steering wheel. Now lift the electronic module upwards until it plugs into the steering wheel Clockspring and it's clips latch on into position.


Now, elevate the lower steering column cover and fasten it into place with the two screws on each side.


Place the steering wheel into position paying special attention to the center markings on the steering wheel and center column. Make sure they are alligned to ensure proper installation. Also, make sure the top brown wires are snuggly fit into their designated space, so they don't get pinched when you install the airbag.


Now, fasten the steering wheel by tightening the center bolt back into postion. Plug the yellow steering wheel airbag plug into it's harness, and make sure it clicks into position for proper connection or else airbag may not deploy.


Place the top steering column cover into position and press down on it until it clicks into a fastened position.


Place the steering wheel airbag into position, making sure the connector wires of the yellow plug are not going to be pinched and press it into position until the metal clips snap into place on both sides.


Now, ***with the steering wheel assembled and in the center postion, remove the key from the ignition***. Then reconnect the battery. Now, arm and disarm the alarm system to inactivate the engine immobilizer. ***When you start the car keep the steering wheel in the center position as we mentioned earlier.*** The ESP light and the yellow steering wheel light on the dash may come ON, because the steering wheel angle calibration must be done. Now turn the car off, push the key in until the dash lights up and scan the car at this time with VAG-COM. It may give you multiple fault codes because the battery was disconnected and due to the steering wheel maintenance. Clear all the fault codes and the one that will remain is the following:

1 Fault Found:
8 - Steering Angle Sensor (G85)
005 - No or Incorrect Basic Setting / Adaptation

The ESP and Yellow steering wheel lights on the dash will still be there after clearing the codes. Now, we will calibrate the steering wheel angle.
With the engine running and the steering wheel in center position, turn the steering wheel all the way to the right first, then all the way to the left, then back to the center and then drive the car forward at no more than 20 MPH. This should turn off the EPC, yellow steering wheel light, and calibrate the steering wheel angle. If this doesn't do it then you will need to calibrate with VAG-COM.