Volkswagen Repair: 2004 Passat wagon suddenly will not start, variable resistor, clutch pedal


Question
I have a 2004 Passat wagon.  I have been having trouble w ith the digital MPG display because it continously changes numbers.  I have not had any other problems.  Today, I went to start the car and it will make no sound at all.  It will not turn over or anything.  This is a 5 speed manual.

Thanks,
Stefanie


Answer
Hi Stephanie;
Do the lights in the dash panel insert come on?  This almost sounds like an ignition switch electrical portion has failed.  Although since it is a 5 speed manual car it could just be the clutch safety switch.  There is a switch that registers engaged, disengaged, and position.  It is at the clutch pedal assembly.  One part of the circuit is in back of the clutch "swing arm" and located in a steel angle with an electrical connector on the back of it.  It disengages the cruise control if the switch is closed.  The other 2 parts of this circuit/switch/assembly/unit are up near the top of the swing arm.  One part is a variable resistor that shows the position of the clutch pedal to the ECM, and the other part is the part that I think may have failed.  It is the safety portion of the switch.  I have seen a number of these assemblies wiring harness components tangled up in the noise reduction padding under the dash.  How many miles on your 2004? Is it still under warranty?  Anyway, if the ECM doesn't see the signal from the clutch pedal position sensor, saying that it is completely depressed, then it won't make any noise at all!  Call your local dealer, and have them repair it under warranty, if applicable, or available.  They are not that terribly difficult to get to, but as I said earlier, there are 3 parts to it.  The position sensor isn't my suspect, the completely depressed switch is.  If you can, or if you have some "torx" bit tools.  You will need a 20, and a 25.  Get under the dash, and remove the sound reduction insulating panel.  You will need a small "pick" of some kind to release the little plastic covers over some of the screw heads, but just try to pull the panel down, after you get a couple out, and you will be able to find the others with this method.  Remember, they were a little tricky under here, and there is on inside a hollow little opening, and there is another one up inside the spot for the owners manual, and there is one on the console, that has a little plastic cover over it...etc.  Just be patient, and a little careful.  Once the panel is out of the way, the hard part starts.  There are 2 switches easily visible.  One on the brake pedal, and one on the clutch pedal.  Remove the one on the clutch pedal, and remove the connector.  Now you will need a flashlight, and an "inspection mirror."  Follow the clutch pedal up a little higher on the swing arm, and there will be 2 more connectors with wires.  One will be sort of a fan shape, and the other will be like the one you pulled out down below.  The one that is similar to the lower one is the culprit, and needs to be replaced.  Remove it, replace it, reconnect it, and reconstruct all the other stuff, in reverse order, and you are done.  Car should start, and run just fine.  The MFA(multi-funktion anzeige)(multi function display) problem is either in the dash panel insert, where the lights are, or more than likely in the handle on the side of the steering wheel.  The switches usually go bad before the rest of the system does.
Good luck, Stefanie.  I hope this helps.