VW Golf Variant Service Manual [PDF]

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Edition 07.2010

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Service

Service List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups

27 - Starter, current supply, CCS 90 - Gauges, instruments

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92 - Windscreen wash/wipe system

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94 - Lights, bulbs, switches - exterior 96 - Lights, bulbs, switches - interior

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Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2010 Volkswagen AG, Wolfsburg Downloaded from www.Manualslib.com manuals search engine

D3E801EB102

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

Contents 27 - Starter, current supply, CCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1 1.1 1.2 1.3

Battery A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Types of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning notices and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery terminal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1

2 3 4 4.1

Checking battery A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging battery A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AG. Volkswagen AG d agen Disconnecting and connecting A . . . . . . . .o.es. n. . . . . . . . . . . . . . . . . . . . . . . . . . . . wbattery ot g olks V y ua compartment) . . . . . . . . . . Disconnecting and connecting battery A ( battery A in engine b ra ed

2 3 4 4

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Removing and installing battery A . . . . . . . . . . . . . . . . . . . . . .ee. o.r . . . . . . . . . . . . . . . . . . . . tho ac au s Removing and installing battery A ( battery A in engine compartment) ................ s Starter B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking starter B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing starter B (automatic gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing starter B (DSG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing starter B (manual gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Securing battery positive wire on alternator C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking alternator C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator C 1.4l petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator C 1.4l FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator C 1.4l, TSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator C 1.6l petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator C 1.6l FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator C 2.0l FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator C 2.0l TFSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator C 2.5l petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator C 1.9l diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator C 1.9l diesel engine with diesel particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator C 2.0l SDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator C 2.0l diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator C 2.0l CR diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator C 2.0l TSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing poly-V belt pulley on alternator C . . . . . . . . . . . . . . . . . . . . . . . . Voltage regulator C1 for alternator C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rrectness of i t to the co nform spec a t ion h re wit in t his

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5 5.1 6 6.1 6.2 6.3 6.4 7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15 7.16 7.17 7.18 7.19 8

7 7 13 13 14 35 60 88 88 88 89 90 95 100 106 110 114 121 128 131 138 144 148 153 158 163 168 172

90 - Gauges, instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 2 2.1

Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing dash panel insert (up to MY2009) . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing dash panel insert (from MY2010) . . . . . . . . . . . . . . . . . . . . . . . . Back of dash panel insert (up to MY2009) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back of dash panel insert (from MY2010) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pin assignment of connectors at dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning lamp symbols on dash panel insert (up to MY2009) . . . . . . . . . . . . . . . . . . . . . . Warning lamp symbols on dash panel insert (from MY2010) . . . . . . . . . . . . . . . . . . . . . . . . Service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resetting service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173 173 174 175 176 176 176 176 178 180 180

92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Contents

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deactivating wiper motor control unit J400 APP function . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing wiper arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting wiper blade park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing joint-free wiper blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing rain and light sensor G397 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coding rain and light sensor G397 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

181 181 183 183 188 188 190 190 192

2 2.1 2.2 2.3 2.4 2.5 2.6 3 3.1 3.2 3.3 3.4 4 4.1 4.2 4.3 5 5.1 5.2 5.3 5.4 5.5 5.6 6 7

Windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing washer fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing windscreen and rear pump V59 . . . . . . . . . . . . kswagen Awasher . Volwindow G do gen AG es n G33 . . . . . . . . . . . . . . . . . . wawasher Removing and installing windscreen fluid level sender s k l ot g o yV Removing and installing windscreen washer system spray jets u.a.ra.n . . . . . . . . . . . . . . . . . . . db ir se t ho Adjusting windscreen washer system spray jets . . . . . . . . . . . . . . .ee.or. . . . . . . . . . . . . . . . ut ac a ss Rear window wiper system .................................................. Assembly overview - rear window wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing rear window wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting rear window wiper park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing joint-free wiper blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing washer jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting spray jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing headlight washer system pump V11 . . . . . . . . . . . . . . . . . . . . . . Removing and installing spray jet pop-up cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing spray jet assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting headlight washer system spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bleeding headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Washer fluid line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

194 194 195 197 198 199 199 200 200 200 202 203 205 205 206 206 207 207 208 209 209 210 210 212 213

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1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8

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94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Contents

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Headlights with halogen bulbs (up to MY2009) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting headlight installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing headlight range control motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing headlight retaining tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Converting headlights for use when driving on the left or right . . . . . . . . . . . . . . . . . . . . . . Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlights with halogen bulbs (from MY2009) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting headlight installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing headlight range control motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing headlight securing tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Converting headlights for use when driving on the left or right . . . . . . . . . . . . . . . . . . . . . . agen lksw Vo by

1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8

214 214 215 217 218 224 231 233 235 236 236 236 238 240 241 247 251 254

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AG. Volkswagen AG d agen o Headlights with gas discharge ksw bulbs (up to MY2009)es n.ot. . . . . . . . . . . . . . . . . . . . . . . . . . . l o V g by Operation and safetyednotes for gas discharge bulbs . . . .ua. ra. n. . . . . . . . . . . . . . . . . . . . . . . . t ris o Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ee.o.r . . . . . . . . . . . . . . . . . . . . . th a au s Removing ands installing headlight . . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . . . Adjusting headlight installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing headlight range control motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing gas discharge light control unit . . . . . . . . . . . . . . . . . . . . . . . . . . Control unit for headlight range control J431 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle level sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing headlight securing tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Converting headlights for use when driving on the left or right . . . . . . . . . . . . . . . . . . . . . . Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlights with gas discharge bulbs and cornering lights (from MY2010) . . . . . . . . . . . . . . General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting headlight installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight starter for gas discharge bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power output module for headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight range control unit J431 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight range control motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swivel module position sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight screen adjustment solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle level sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED module for daytime running light and side light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Converting headlights for use when driving on the left or right . . . . . . . . . . . . . . . . . . . . . . Repairing headlight securing tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - fog lights (up to MY2009) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - fog lights (from MY2010) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fog lights (up to MY2009) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fog lights (from MY2010) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fog light/cornering light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bulb for turn signal repeater light and entry light in exterior mirror . . . . . . . . . . . . . . . . . . . . Removing and installing turn signal bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing entry light in exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing front side marker light in front bumper . . . . . . . . . . . . . . . . . . . .

257 258 258 261 262 262 262 268 271 272 275 276 277 277 278 278 279 280 282 282 287 288 290 292 292 293 294 294 294 296 296 297 297 298 298 299 300 301 302 302 302 305

8 9 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11

Rear side marker bulb (USA/Canada only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tail lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - tail light in side panel (bulbs) - saloon . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing tail light in side panel (bulbs) - saloon . . . . . . . . . . . . . . . . . . . . . . Removing and installing tail light bulb carrier in side panel - saloon . . . . . . . . . . . . . . . . . . Tail light in side panel (LED) - saloon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing tail light in side panel (LED) - saloon . . . . . . . . . . . . . . . . . . . . . . Assembly overview - tail light in rear lid - saloon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing tail light in rear lid - saloon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing tail light bulb holder in rear lid - saloon . . . . . . . . . . . . . . . . . . . . Assembly overview - tail light - Variant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing tail light - Variant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing tail light bulb holder - Variant . . . . . . . . . . . . . . . . . . . . . . . . . . . .

306 307 307 307 308 309 309 310 311 311 313 313 314

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Contents

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Removing and installing number plate lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

11 11.1 11.2

Additional brake lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 Removing and installing additional brake light bulb M25 - saloon . . . . . . . . . . . . . . . . . . . . 316 Removing and installing additional brake light bulb M25 - estate . . . . . . . . . . . . . . . . . . . . 316

12 12.1 12.2 12.3 12.4

Steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering column electronics control unit J527 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

319 320 320 327 328

13 13.1 13.2 13.3

Ignition/starter switch and lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing steering lock housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing ignition/starter switch D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

330 330 330 332

14 14.1 14.2 14.3 14.4 14.5 14.6 14.7 14.8 14.9 14.10 14.11 14.12 14.13 14.14 14.15 14.16 14.17 14.18 14.19 14.20 14.21 14.22 15 15.1 15.2 15.3 15.4 15.5 15.6 15.7 15.8 16 16.1 16.2 16.3 16.4 17

Parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - 4-channel parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - 8-channel parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing parking aid control unit J446 (4-channel) - saloon . . . . . . . . . . . . Removing and installing parking aid control unit J446 (4-channel) - estate . . . . . . . . . . . . Removing and installing parking aid control unit J446 (8-channel) . . . . . . . . . . . . . . . . . . Coding parking aid control unit J446 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust optical display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing rear parking aid senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing front parking aid senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bonding sender holder in bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing parking aid senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing parking aid senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing rear parking aid warning buzzer H15 - saloon . . . . . . . . . . . . . . Removing and installing rear parking aid warning buzzer H15 - estate . . . . . . . . . . . . . . . . Adjusting rear parking aid warning buzzer H15 volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting rear parking aid warning buzzer pitch H15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing front parking aid warning buzzer H22 . . . . . . . . . . . . . . . . . . . . Adjusting front parking aid warning buzzer H22 volume . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting front parking aid warning buzzer pitch H22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking aid final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking parking aid button E266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Park assist steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - park assist steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Park assist steering control unit J791 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Park assist steering senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing park assist steering sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front parking aid warning buzzer H22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear parking aid warning buzzer H15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Park assist steering/parking aid button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reversing camera system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview – reversing camera system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing reversing camera R189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibrating reversing camera system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing trailer socket U10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

334 334 335 337 338 338 339 341 341 342 345 347 349 350 351 351 352 352 353 353 354 354 355 357 357 359 360 363 366 367 369 370 372 372 373 373 375 380

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96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382 1

iv

Lights and switches in engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382

Contents

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 382 383 383 384 385 386

3.4 3.5 3.6 3.7 3.8

Removing and installing bonnet contact switch F266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lights and switches in dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing light switch E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing glove compartment light W6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing glove compartment light switch E26 . . . . . . . . . . . . . . . . . . . . . . Removing and installing regulator for switch and instrument illumination E20 . . . . . . . . . . Removing and installing warning lamp for airbag deactivated on front passenger side K145 ...................................................................... Removing and installing hazard warning light switch E3 . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing footwell lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing key operated switch to deactivate front passenger side airbag E224 ...................................................................... Lights and switches in front doors and B-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing window regulator switch in front passenger door E107 . . . . . . . . Removing and installing switch module for mirror adjustment on driver side . . . . . . . . . . . . Removing and installing driver side interior locking button for central locking system E308 ........................................................................ Components - front door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing switch module for driver side window regulator . . . . . . . . . . . . . . Removing and installing remote release button for fuel filler flap and rear lid E463 . . . . . . Removing and installing interior monitoring/vehicle inclination deactivation switch . . . . . . Removing and installing central locking deadlock function warning lamp -SAFE- K133 . .

4 4.1 4.2 5 5.1 5.2 6 6.1 6.2 6.3 6.4 6.5 6.6 7 7.1 7.2 7.3 8 8.1 8.2 8.3 9 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 10

Lights and switches in rear doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components - rear door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing rear window regulator switch in door . . . . . . . . . . . . . . . . . . . . . . Lights and switches in luggage compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing luggage compartment light W3 . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing rear lid lock unit F256 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lights and switches in roof trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front interior light W1 (without sunroof) . . . . . . . . e. n. A. G. ..V.o.lk.sw. a.g.e.n .AG ................... do ag Front interior light W1 (with sunroof) . . . . . V. o.lk.sw. . . . . . . . . . . . . . . . . . e. s.n.ot. g. . . . . . . . . . . . y ua db r Rear interior light W45 (vehicles without iseanti-theft alarm) . . . . . . . . . . . . . . . . .an.te. . . . . . . . r o e h t Rear interior light W45 (vehicles with u anti-theft alarm) up to MY2009 . . . . . . . . . .or.a. . . . . c sa s Removing and installing illuminated vanity mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing garage door operating unit E284 . . . . . . . . . . . . . . . . . . . . . . . . Lights and switches in centre console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Buttons in centre console storage compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing buttons in centre console storage compartment . . . . . . . . . . . . . . Removing and installing AC/DC converter with socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . immobiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing immobiliser control unit J362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . immobiliser reader coil D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-theft alarm (ATA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activating and deactivating anti-theft alarm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing ultrasonic sensor (rear interior light) (up to MY2009) . . . . . . . . . . Removing and installing ultrasonic sensor (rear left-hand side of roof) (up to MY2009) . . Anti-theft alarm sensor G578 (from MY2010) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing vehicle inclination sender G384 (up to 2006) . . . . . . . . . . . . . . . . Vehicle inclination sender G384 (from MY2010) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interior monitoring sensor G273 (from MY2010) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Central locking and anti-theft alarm system aerial R47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing alarm horn H12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

400 400 400 402 402 403 404 404 407 411 413 416 417 418 418 418 420 423 423 423 423 428 428 430 431 431 432 434 434 435 435 435 438

387 388 388 390 392 392 393 393 394 395 396 397 398

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1.1 2 2.1 2.2 2.3 2.4 2.5

Contents

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 10.1 10.2

Removing and installing treble horn H2 / bass horn H7 . . . . . . . . . . . . . . . . . . . . . . . . . . 438 Checking treble horn H2 / bass horn H7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438

97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439 1

Vehicle diagnosis, testing and information systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439

2 2.1

Removing and installing fuse holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 Removing and installing fuse holder on left of dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . 440

3 3.1 3.2

Removing and installing relay carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442 Removing and installing relay carrier on left beneath dash panel . . . . . . . . . . . . . . . . . . . . 442 Removing and installing relay carrier on onboard supply control unit J519 (up to MY2009) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443 Removing and installing relay carrier on onboard supply control unit J519 (from MY2010) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445 Electronics boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446 Removing and installing electronics box on left side of engine compartment . . . . . . . . . . 446 Control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 Onboard supply control unit J519 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 Data bus diagnostic interface J533 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467 Convenience system central control unit J393 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472 Driver door control unit J386 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477 Front passenger door control unit J387 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478 Coding rear left door control unit J388 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479 Coding rear right door control unit J389 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480 Trailer detector control unit J345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481 Garage door operation control unit J530 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486 Wiring harness and connector repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488 Removing and installing engine wiring harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489 Operation and safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489 Installation notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 Assembly overview - 2.0 TDI engine /CR engine (engine code CBEA) wiring harness . . . . 491 Removing and installing engine wiring harness, 2.0 l, TDI/CR engine (EC/CBEA) . . . . . . 497 AG. Volkswagen Specified torques for wires, lines and cables . . . . . . . . . . l.ks.w.a.ge. n. . . . . . . . . . . A. G . .do. e.s.n . . . . 507 ot o V y b Specified torques for E-box on left side of engine compartment . . . . . . . . . . . . . . . . . .g.ua.ra 507 d nte ir se Specified torques for trailer detector control unit J345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507 eo tho au ss

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Contents

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4 4.1 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 6 7 7.1 7.2 7.3 7.4 8 8.1 8.2

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3.3

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

27 –

Starter, current supply, CCS

1

Battery -AWARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 1 !

1.1

Types of battery

All the instructions and information for this manual are found in the workshop manual „Electrical System, General Information“. A link to this workshop manual is not possible at present for tech‐ nical reasons. Please select the workshop manual „Electrical System, General Information“ manually in ELSA.

1.2

Warning notices and safety regulations

All the instructions and information for this manual are found in the workshop manual „Electrical System, General Information“. A link to this workshop manual is not possible at present for tech‐ nical reasons. Please select the workshop manual „Electrical System, General Information“ manually in ELSA.

1.3

Battery terminal connection

All the instructions and information for this manual are found in the workshop manual „Electrical System, General Information“. A link to this workshop manual is not possible at present for tech‐ . Volkswagen AG do „Electrical nical reasons. Please select the workshop manual n AG age e ksw l o System, General Information“ manually in ELSA. s not g yV ua ran tee

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1. Battery A

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1

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

2

Checking battery -A-

All the instructions and information for this manual are found in the workshop manual „Electrical System, General Information“. A link to this workshop manual is not possible at present for tech‐ nical reasons. Please select the workshop manual „Electrical System, General Information“ manually in ELSA.

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Rep. gr.27 - Starter, current supply, CCS

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

3

Charging battery -A-

All the instructions and information for this manual are found in the workshop manual „Electrical System, General Information“. A link to this workshop manual is not possible at present for tech‐ nical reasons. Please select the workshop manual „Electrical System, General Information“ manually in ELSA.

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3. Charging battery A

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3

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

4

Disconnecting and connecting bat‐ tery -A-

4.1

Disconnecting and connecting battery A- ( battery -A- in engine compartment) WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 1 ! Disconnect battery -A- ⇒ page 5 Reconnecting battery -A- ⇒ page 5 .

4.1.1

Assembly overview - battery -A. Volkswagen AG gen AG does not gu ara nte eo ra c

2 - Nut ❑ 6 Nm

3 - Positive wire battery termi‐ nal clamp ❑ Observe notes for bat‐ tery terminal clamp bolt ⇒ page 1 . 4 - Nut ❑ 6 Nm

5 - Battery -A❑ Removing and installing ⇒ page 7 6 - Clamping plate 7 - Bolt ❑ 35 Nm

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1 - Earth wire battery terminalVolkswa y clamp db ise r ❑ Observe notesufor tho bat‐ a tery pole terminal clamp ss bolt ⇒ page 1 .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

4.1.2

Disconnecting battery -ACaution

♦ Always make sure that the electrical system of the vehicle is protected by disconnecting the battery -A- before any work on the electrical system starts. ♦ Do not unfasten or remove the earthing cable from your body. Only remove the negative terminal (-) of the battery -A- . ♦ The positive terminal (B+) of the battery -A- is only allowed to be removed if the battery -A- has been removed from the vehicle. ♦ Observe warning notices and safety regulations ⇒ page 1 .

Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Carry out following procedures:

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– Then unscrew battery positive terminal clamp -2- from battery positive terminal.

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Connecting battery -A-

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– First unscrew battery earth negative terminal.

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Observe notes for battery pole terminal clamp bolt ⇒ page 1 .

4. Disconnecting and connecting battery A

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5

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-

Note

After battery -A- has been connected and ignition is switched on, ESP and TCS warning lamp -K155- will light up permanently. The ESP and TCS warning lamp -K155- will go out automatically when the vehicle is driven at 15 to 20 km/h in a straight line. This has effect of reactivating steering angle sender -G85- .

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Caution

Carry out following procedures:

– Fit battery positive wire clamp -2- to positive terminal of battery -A- and tighten bolt to specified torque ⇒ page 4 . – Fit battery earth wire clamp -1- to negative terminal of battery -A- and tighten bolt to specified torque ⇒ page 4 . – Carry out steps as detailed in the table. Steps after connecting battery -A-

Performed

Rep. gr.27 - Starter, current supply, CCS

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You can also print out the table.

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Switch ignition on and off again using ignition key. Read fault memory ⇒ Vehicle diagnostic, testing and informa‐ tion system VAS 5051 Clock: Check time setting and reset. Open all electric windows fully and close again. Test function of all electrical consumers.

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When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

5

Removing and installing battery -A-

5.1

Removing and installing battery -A( battery -A- in engine compartment) WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 1 ! Vehicles with a petrol engine ⇒ page 7 Vehicles with a diesel engine ⇒ page 9

5.1.1

Assembly overview - battery -A-

1 - Earth wire battery terminal clamp ❑ Notes on bolted connec‐ tion of the battery termi‐ nals ⇒ page 1 2 - Nut ❑ 6 Nm 3 - Positive wire battery termi‐ nal clamp . Volkswagen AG gen AG does not ❑ Notes on bolted connec‐ Volkswa gu y b ara tion of the battery termi‐ d e nte nals ⇒ page 1 thoris eo au ss

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5 - Battery -A❑ Removing and installing ⇒ page 7 6 - Clamping plate 7 - Bolt ❑ 35 Nm

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Vehicles with a petrol engine

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5.1.2

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4 - Nut ❑ 6 Nm

Special tools and workshop equipment required

5. Removing and installing battery A

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7

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Torque wrench -V.A.G 1331-

Carry out following procedures: Removing – Disconnect battery -A- ⇒ page 5 . – Pull panel of battery housing out upwards in direction of arrow.

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Rep. gr.27 - Starter, current supply, CCS

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– Undo bolt -1- and remove clamping plate -2-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Fold up handles -arrows- upwards and remove battery -A- . Installing Caution

A loosely fitted battery -A- creates the following dangers: ♦ Shortened service life due to damage from vibration (dan‐ ger of explosion) ♦ The cells in the battery -A- will be damaged if the battery -A- is not secured correctly. ♦ Damage to battery housing due to clamping plate (possi‐ bility of acid leaking, with high consequential costs) ♦ Poor crash safety Carry out installation in the reverse sequence, noting the follow‐ ing: – Tighten threaded connections to specified torque ⇒ page 7 . – After installing, check that battery -A- is seated securely. – Connect battery -A- ⇒ page 4 . Caution

When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 .

5.1.3

Vehicles with a diesel engine

Special tools and workshop equipment required

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♦ Torque wrench -V.A.G 1331-

9

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Spring-type clip pliers -VAS 5024A-

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– Pull engine cover upwards -arrows A- and forwards -arrow B-.

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– Disconnect connector -1- and release spring-type clip -2- us‐ ing spring type clip pliers -VAS 5024A- .

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10

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– Pull vacuum hose -arrow- off air filter housing.

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s – Disconnect battery s-A⇒ page 4 .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove bolt of air filter housing -arrow-.

– Release locking lugs -arrows- and take off cover.

– Pull hose -arrow- off air filter housing and remove. – Pull air filter housing upwards out of brackets and remove.

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– Pull panel of battery housing out upwards -in direction of arrow-.

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5. Removing and installing battery A

11

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤y Volks b ed Electrical system - Edition 07.2010 ris

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– Undo bolt -1- and remove clamping plate -2-.

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– Fold up handles -arrows- upwards and remove battery -A- . Installing Caution

♦ Poor crash safety Carry out installation in the reverse sequence, noting the follow‐ ing: – Tighten bolt for air filter housing -arrow- to 10 Nm. – Tighten threaded connections to specified torques ⇒ page 7 . – After installing, check that battery -A- is seated securely. – Connect battery -A- ⇒ page 4 . Caution

When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 .

12

Rep. gr.27 - Starter, current supply, CCS

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♦ Damage to battery housing due to clamping plate (possi‐ bility of acid leaking, with high consequential costs)

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♦ The cells in the battery -A- will be damaged if the battery -A- is not secured correctly.

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♦ Shortened service life due to damage from vibration (dan‐ ger of explosion)

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A loosely fitted battery -A- creates the following dangers:

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

6

Starter -B-

Checking starter -B-

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6.1

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

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– Connect vehicle diagnosis, testing and information system VAS 5051B- .

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When cedure described in the workshop manual must be strictly observed ⇒ page 4 .

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In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. AG.

– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system ♦ 27 - Starter, current supply ♦ Electrical components ♦ B - Starter

6. Starter B

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

6.2

Removing and installing starter -B- (au‐ tomatic gearbox)

6.2.1

Assembly overview - starter -B-

1 - Starter -B❑ Checking ⇒ page 13 2 - Battery positive wire con‐ nection to starter -B3 - Nut ❑ 15 Nm 4 - Bolt ❑ 75 Nm 5 - Protective cap

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Vehicles with 1.6l petrol engine

Special tools and workshop equipment required

14

Rep. gr.27 - Starter, current supply, CCS

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6.2.2

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♦ Earth wire to automatic gearbox housing - 15 Nm

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♦ Air filter housing bolt to body: 10 Nm

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Torque wrench -V.A.G 1331-

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– Disconnect battery -A- ⇒ page 4 .

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Removing

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♦ Spring-type clip pliers -VAS 5024A-

– Loosen spring-type clip -1- using spring-type clip pliers -VAS 5024A- and remove bolt -2-. AG.

– Release hose -3- and pull it off the air filter housing.

6. Starter B

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15

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull air filter housing upwards on right-hand side out of rubber mounting -arrow-. – Take air filter housing out of vehicle.

– Slide protective cap in direction of -arrow- off solenoid switch.

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– Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 .

– Remove nut -1- from lower starter bolt.

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16

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– Remove wiring retainer -2-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove lower bolt -arrow- from starter.

– Remove nut -1- from upper starter bolt. – Remove wiring retainer -2-.

– Remove upper bolt -arrow- from starter.

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– Remove starter -B- from vehicle upwards.

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– Remove nut of earth wire -1- and place end of earth wire -2to one side.

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– Tighten threaded connections to specified torques ⇒ page 14 .

6.2.3

Vehicles with 1.6l FSI engine

Special tools and workshop equipment required

6. Starter B

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Torque wrench -V.A.G 1331-

♦ Torque wrench -V.A.G 1332-

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Carry out following procedures:

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– Disconnect battery -A- ⇒ page 4 . – Slide protective cap in direction of -arrow- off solenoid switch.

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AG.

Rep. gr.27 - Starter, current supply, CCS

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18

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– Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 .

do c um en

– Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove nut -1- from lower starter bolt. – Remove wiring retainer -2-.

– Remove lower bolt -arrow- from starter.

– Remove nut -1- from upper starter bolt.

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– Remove wiring retainer -2-.

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– Remove upper bolt -arrow- from starter.

6. Starter B

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19

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove nut of earth wire -1- and place end of earth wire -2to one side. – Remove starter -B- from vehicle upwards. Installing

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Vehicles with 2.0l FSI engine

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-

cop yri gh t . Co py i

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Removing – Disconnect battery -A- ⇒ page 4 .

20

Rep. gr.27 - Starter, current supply, CCS

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AG.

Carry out following procedures:

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♦ Spring-type clip pliers -VAS 5024A-

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♦ Torque wrench -V.A.G 1332-

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6.2.4

tee or ac

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t – Tighten threaded connections to specified torques au ss . ⇒ page 14

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Disconnect connector -arrow-.

– Unclip vacuum hose out of retainer -arrow-.

– Loosen spring-type clip -arrow- from hose -1- using springtype clip pliers -VAS 5024A-en. AG. Volkswagen AG ag ksw

does not gu ara nte eo ra c

Vol housing. – Pull hose -1- off airbyfilter

– Open retainer -arrow- on front of air filter housing and remove line -1-.

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6. Starter B

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21

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove bolt of air filter housing -arrow-.

– Pull air filter housing upwards on right-hand side out of rubber mounting -arrow-.

– Loosen spring-type clip -1- using spring-type clip pliers -VAS 5024A- . – Pull hose -2- off connection. – Carefully lift up air filter housing out of vehicle as far as wiring allows.

– Disconnect connector -arrow- on rear of air filter housing.

AG.

Prote cted by

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agen lksw Vo by

c o p yri gh t. C op yi

Rep. gr.27 - Starter, current supply, CCS

ht rig py Co t.

22

rrectness of i t to the co nform spec a t i h re o n in wit thi sd o cu m en

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Take air filter housing out of vehicle. – Slide protective cap in direction of -arrow- off solenoid switch.

– Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 .

– Remove nut -1- from lower starter bolt. – Remove wiring retainer -2-.

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm te o a itte ir v du p or nl f e ng

ility ab y li an pt ce

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– Remove lower bolt -arrow- from starter.

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6. Starter B

23

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove nut -1- from upper starter bolt. – Remove wiring retainer -2-.

– Remove upper bolt -arrow- from starter.

– Remove nut of earth wire -1- and place end of earth wire -2to one side. – Remove starter -B- from vehicle upwards. Installing Install in the reverse order of removal. When doing this, note the following: n AG. Volkswagen AG do es n wage ot g olks V y ua db ran e ir s tee o h t or u ac a ss

– Tighten threaded connections to specified torques ⇒ page 14 .

Special tools and workshop equipment required

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AG.

Rep. gr.27 - Starter, current supply, CCS

agen lksw Vo by

24

Prote cted by c o py rig ht . C op yi

♦ Torque wrench -V.A.G 1331-

ht rig py Co t.

Vehicles with 2.5l petrol engine

rrectness of i t to the co nform spec at i h re o n wit in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m m ot p r co erm o e t a itte v i r du p or nl f e ng

ility ab y li an pt ce

6.2.5

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Torque wrench -V.A.G 1332-

♦ Spring-type clip pliers -VAS 5024A-

Carry out following procedures: Removing

– Disconnect battery -A- ⇒ page 4 .

– Pull engine cover off upwards -arrows-.

rrectness of i t to the co nform spec at i h re o n wit in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m m ot p r co erm o e t a itte v i r du p or nl f e g n

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– Separate connector -1-, release spring-type clip -2- with spring-type clip pliers -VAS 5024A- and pull off vacuum hoses -3-. – Pull air filter housing upwards out of brackets and remove.

6. Starter B

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25

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Push down protective cap in direction of -arrow- from solenoid n AG. Volkswagen AG do switch. e wage

s no t gu ara nte eo ra c

– Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 .

Prote cted b y c op yri gh t . Co py i

26

Rep. gr.27 - Starter, current supply, CCS

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AG.

– Remove lower bolt -arrow- from starter.

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– Remove wiring retainer -2-.

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– Remove nut -1- from lower starter bolt.

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n AG. Volkswagen AG do es n wage ot g olks V ua by d ran ir se tee o h Golf Variant 2007 ➤ , Golf Variant 2010 ➤ t or , Jetta 2005 ➤ ac au s Electrical system - Edition 07.2010 s

– Remove nut -1- from upper starter bolt. – Remove wiring retainer -2-.

rrectness of i t to the co nform spec a t ion h re wit in t his

– Remove upper bolt -arrow- from starter. – Lower starter -B- out of vehicle.

AG.

6.2.6

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– Tighten threaded connections to specified torques ⇒ page 14 .

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Install in the reverse order of removal. When doing this, note the following:

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Installing

Vehicles with 1.9l diesel engine

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-

♦ Torque wrench -V.A.G 1332-

6. Starter B

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27

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 olkswagen AG en AG. V does not gu ara nte eo ra c

wag ♦ Spring-type clip pliers olks -VAS 5024A-

rrectness of i t to the co nform spec a t i h re o n in wit thi s

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ss

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Carry out following procedures: Removing

– Disconnect battery -A- ⇒ page 4 . – Pull engine cover upwards -arrows A- and forwards -arrow B-.

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AG.

Prote cted by c o py rig ht . C op yi

– Disconnect connector -1- and release spring-type clip -2- us‐ ing spring type clip pliers -VAS 5024A- .

– Pull vacuum hose -arrow- off air filter housing.

28

Rep. gr.27 - Starter, current supply, CCS

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove bolt of air filter housing -arrow-.

– Release locking lugs -arrows- and take off cover.

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– Pull hose -arrow- off air filter housing and remove.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Pull air filter housing upwards out of brackets and remove.

– Push down protective cap in direction of -arrow- from solenoid switch.

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ht rig py Co t.

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AG.

Prote cted by c o py rig ht . C op yi

6. Starter B

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29

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 .

– Remove wiring retainer -2-.

– Remove lower bolt -arrow- from starter.

Prote cted by

Rep. gr.27 - Starter, current supply, CCS

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AG.

30

agen lksw Vo by

c o p yri gh t. C op yi

– Remove wiring retainer -2-.

ht rig py Co t.

– Remove nut -1- from upper starter bolt.

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– Remove nut -1- from

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s ri o eo h t u ra a c lower ss starter bolt.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove upper bolt -arrow- from starter.

– Remove nut of earth wire -1- and place end of earth wire -2to one side in direction of battery -A- . – Remove starter -B- from vehicle upwards. Installing Install in the reverse order of removal. When doing this, note the following: – Tighten threaded connections to specified torques ⇒ page 14 .

Vehicles with 2.0l SDI engine urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e ng

ility ab y li an pt ce

6.2.7

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h t u ra a c ss

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-

rrectness of i t to the co nform spec a t i h re o n in wit thi s

♦ Torque wrench -V.A.G 1332-

do c um en

ht rig py Co t.

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AG.

Prote cted by

cop yri gh t . Co py i

6. Starter B

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31

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Spring-type clip pliers -VAS 5024A-

Carry out following procedures: Removing – Disconnect battery -A- ⇒ page 4 . – Pull engine cover upwards -arrows A- and forwards -arrow B-.

ility ab y li an pt ce

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AG.

Rep. gr.27 - Starter, current supply, CCS

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Prote cted by c o py rig ht . C op yi

32

ht rig py Co t.

r fo ng

– Pull off vacuum hose -arrow-.

rrectness of i t to the co nform spec a t i h re o n in wit thi sd o cu m en

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–

un le

–

n AG. Volkswagen AG do es n wage ot g olks V y ua Loosen spring-type clip -1- using spring-type clip d b pliers -VAS ran e is tee r 5024A- and disconnect connector -2-. o h t or u ac a Remove bolt -3-. ss

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull air filter housing upwards on right-hand side out of rubber mounting -arrow-. – Take air filter housing out of vehicle.

– Slide protective cap in direction of -arrow- off solenoid switch.

– Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-.

– Unscrew earth wire from starter bolt -arrow-.

rrectness of i t to the co nform spec a t i h re o n in wit thi sd o cu m en

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Prote cted by

cop yri gh t . Co py i

6. Starter B

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33

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ AG. Volkswagen AG d Electrical system - Edition 07.2010 agen o exterior;

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Rep. gr. 50 .

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– Remove nut -1- from lower starter bolt.

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Installing Install in the reverse order of removal. When doing this, note the following: – Tighten threaded connections to specified torques ⇒ page 14 .

34

Rep. gr.27 - Starter, current supply, CCS

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agen lksw Vo by

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– Lower starter -B- out of vehicle.

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– Unscrew starter bolt -arrow-.

thi sd o cu m en

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– Remove wiring retainer -2-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

6.3

Removing and installing starter -B(DSG)

6.3.1

Assembly overview - starter -B-

1 - Starter -B❑ Checking ⇒ page 13

3 - Nut ❑ 20 Nm

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t a itte riv du p r o nl f e ng

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5 - Protective cap

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4 - Bolt ❑ M12 = 75 Nm ❑ M10 = 40 Nm

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2 - Battery positive wire con‐ nection to starter -B-

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Not illustrated ♦ Air filter housing bolt to body: 10 Nm

6.3.2

Vehicles with 1.4l TSI engine (90kW)

Special tools and workshop equipment required

6. Starter B

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35

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s ri o eo h t u ra a c ss

pe rm itte d

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♦ Torque wrench -V.A.G 1331-

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♦ Torque wrench -V.A.G 1332-

Removing – Remove air filter housing ⇒ Engine; Rep. gr. 24 . agen lksw Vo by

c o p yri gh t. C op yi

– Release and disconnect connector -1-.

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– Disconnect battery -A- ⇒ page 4 .

AG.

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– Slide protective cap -1- off solenoid switch in direction of -arrow-.

36

Rep. gr.27 - Starter, current supply, CCS

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thi sd o cu m en

r te o iva r rp fo

Carry out following procedures:

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Unscrew nut -1- and remove positive wire -2- from connector thread of solenoid switch.

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o te a itte ir v du p or nl f e ng

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– Remove upper bolt -arrow- from starter.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Remove lower bolt -arrow- from starter. – Lift starter -B- -1- upwards out of vehicle.

AG.

6.3.3

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– Tighten threaded connections to specified torques ⇒ page 35 .

do c um en

Install in the reverse order of removal. When doing this, note the following:

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Installing

Vehicles with 1.4l TSI engine (103kW/ 125kW)

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-

6. Starter B

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37

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Torque wrench -V.A.G 1332-

– Disconnect battery -A- ⇒ page 4 .

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm te o a itte ir v du p or nl f e ng

Removing

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Carry out following procedures:

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d nte ir se o eo h t u ra a c ss

– Pull off vacuum hose at engine cover panel -arrow-.

– Pull off engine cover upwards from its rubber mountings -1and remove it forwards in -direction of arrow-. – Remove air filter housing ⇒ Engine; Rep. gr. 24 .

Downloaded from www.Manualslib.com manuals search engine

AG.

Rep. gr.27 - Starter, current supply, CCS

agen lksw Vo by

Prote cted by c o py rig ht. C op yi

38

ht rig py Co t.

– Slide protective cap -1- off solenoid switch in direction of -arrow-.

do c um en

– Release and disconnect connector -1-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Unscrew nut -1- and remove positive wire -2- from connector thread of solenoid switch.

– Remove upper bolt -arrow- from starter. – Remove noise insulation ⇒ General body repairs, exterior; n AG. Volkswagen AG do es n wage Rep. gr. 50 . o olks

t gu ara nte eo ra c

– Remove charge air hose -1-.

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– Lift starter -B- -1- upwards out of vehicle. agen lksw Vo by

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Installing

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– Remove lower bolt -arrow- from starter.

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Install in the reverse order of removal. When doing this, note the following: AG.

– Tighten threaded connections to specified torques ⇒ page 35 .

6.3.4

Vehicles with 1.6l petrol engine

Special tools and workshop equipment required

6. Starter B

Downloaded from www.Manualslib.com manuals search engine

39

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Torque wrench -V.A.G 1331-

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t itte iva r du p or nl f e ng

– Loosen spring-type clip -1- using spring-type clip pliers -VAS 5024A- and remove bolt -2-. – Release hose -3- and pull it off the air filter housing.

40

Rep. gr.27 - Starter, current supply, CCS

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AG.

– Disconnect battery -A- ⇒ page 4 .

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Prote cted by c o py rig ht . C op yi

Removing

do c um en

Carry out following procedures:

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♦ Spring-type clip pliers -VAS 5024A-

ht rig py Co t.

♦ Torque wrench -V.A.G 1332-

ility ab y li an pt ce

n AG. Volkswagen AG do es n wage ot g olks V ua by d ran ir se tee o h t or ac au s s

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull air filter housing upwards on right-hand side out of rubber mounting -arrow-. – Take air filter housing out of vehicle.

– Slide protective cap in direction of -arrow- off solenoid switch.

– Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-.

– Unscrew earth wire from starter bolt -arrow-.

rrectness of i t to the co nform spec at i h re o n wit in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m m ot p r co erm o e t a itte v i r du p or nl f e g n

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6. Starter B

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41

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Unscrew starter bolt -arrow-. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 .

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e g n

Installing

Install in the reverse order of removal. When doing this, note the following:

6.3.5

Vehicles with 2.0l FSI engine

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-

42

Rep. gr.27 - Starter, current supply, CCS

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AG.

– Tighten threaded connections to specified torques ⇒ page 35 .

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– Lower starter -B- out of vehicle.

Prote cted by c o py rig ht . C op yi

– Unscrew starter bolt -arrow-.

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– Remove wiring retainer -2-.

rrectness of i t to the co nform spec atio h re n wit i n thi sd o c um en

– Remove nut -1- from lower starter bolt.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Torque wrench -V.A.G 1332-

♦ Spring-type clip pliers -VAS 5024A-

Carry out following procedures:

– Disconnect battery -A- ⇒ page 4 .

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AG.

Prote cted by

cop yri gh t . Co py i

– Disconnect connector -arrow-.

ht rig py Co t.

Removing

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– Unclip vacuum hose out of retainer -arrow-.

6. Starter B

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43

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Loosen spring-type clip -arrow- from hose -1- using springtype clip pliers -VAS 5024A- . – Pull hose -1- off air filter housing.

– Remove bolt of air filter housing -arrow-.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

44

Rep. gr.27 - Starter, current supply, CCS

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ht rig py Co t.

– Pull air filter housing upwards on right-hand side out of rubber mounting -arrow-.

rrectness of i t to the co nform spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e g n

ility ab y li an pt ce

– Open retainer line -1-.

n AG. Volkswagen AG do es n wage ot g olks V ua by d ran ir se tee o h t or ac au s -arrow-s on front of air filter housing and remove

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Loosen spring-type clip -1- using spring-type clip pliers -VAS 5024A- . – Pull hose -2- off connection. – Carefully lift up air filter housing out of vehicle as far as wiring allows.

– Disconnect connector -arrow- on rear of air filter housing.

– Take air filter housing out of vehicle. – Slide protective cap in direction of -arrow- off solenoid switch.

– Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-.

rrectness of i t to the co nform spec at i h re o n wit in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m m ot p r co erm o e t a itte v i r du p or nl f e ng

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Prote cted

b y c op yri gh t . Co py i

6. Starter B

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45

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove nut -1- from upper starter bolt. – Remove wiring retainer -2-.

– Remove upper bolt -arrow- from starter. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 .

AG. Volkswagen AG d agen oes

ksw – Disconnect connectors -arrows-. Vol

not gu ara nte eo ra c

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ss

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– Remove nut -1- from lower starter bolt. – Remove wiring retainer -2-.

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AG.

Prote cted by c o py rig ht . C op yi

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ht rig py Co t.

Rep. gr.27 - Starter, current supply, CCS

do c um en

46

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove lower bolt -arrow- from starter. – Lower starter -B- out of vehicle. Installing Install in the reverse order of removal. When doing this, note the following: – Tighten threaded connections to specified torques ⇒ page 35 .

6.3.6

Vehicles with 2.0l TFSI engine

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-

♦ Torque wrench -V.A.G 1332-

rrectness of i t to the co nform spec a t ion h re wit in t his

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t a itte riv du p r o nl f e ng

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d nte ir se o eo h t u ra a c ss

♦ Spring-type clip pliers -VAS 5024A-

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AG.

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Prote cted by c o py rig ht. C op yi

– Disconnect battery -A- ⇒ page 4 .

ht rig py Co t.

Removing

6. Starter B

do c um en

Carry out following procedures:

47

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove bolts -arrows-.

– Disconnect connector -arrow-.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e ng

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d nte ir se o eo h t u ra a c ss

– Loosen spring-type clips -arrow- using spring-type clip pliers VAS 5024A- .

AG.

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agen lksw Vo by

Prote cted by c o py rig ht. C op yi

Rep. gr.27 - Starter, current supply, CCS

ht rig py Co t.

48

do c um en

– Pull engine cover panel upwards -arrows-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Slide protective cap in direction of -arrow- off solenoid switch.

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r eo ho t u ra a c ss

– Remove upper bolt -arrow- from starter.

– Remove lower bolt -arrow- from starter.

c o p yri gh t. C op yi

Install in the reverse order of removal. When doing this, note the following: Prote cted by

6.3.7

AG.

– Tighten threaded connections to specified torques ⇒ page 35 .

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Installing

ht rig py Co t.

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– Remove starter -B- from vehicle upwards.

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urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t a itte v i r d p

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– Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-.

Vehicles with 1.9l diesel engine

Special tools and workshop equipment required

6. Starter B

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49

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Torque wrench -V.A.G 1331-

♦ Torque wrench -V.A.G 1332-

♦ Spring-type clip pliers -VAS 5024A-

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AG.

Prote cted by

cop yri gh t . Co py i

Removing – Disconnect battery -A- ⇒ page 4 . – Pull engine cover upwards -arrows A- and forwards -arrow B-.

50

Rep. gr.27 - Starter, current supply, CCS

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ht rig py Co t.

Carry out following procedures:

rrectness of i t to the co nform spec at i h re o n wit in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m m ot p r co erm o e t a itte v i r du p or nl f e ng

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AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c ss

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Disconnect connector -1- and release spring-type clip -2- us‐ ing spring type clip pliers -VAS 5024A- .

– Pull vacuum hose -arrow- off air filter housing.

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rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Release locking lugs -arrows- and take off cover.

do c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm te o a itte ir v du p or nl f e ng

–

n AG. Volkswagen AG do es n wage ot g olks V y ua b d ran ise tee r o h t or ubolt of air filter housing -arrow-. ac a Remove ss

ht rig py Co t.

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6. Starter B

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51

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull hose -arrow- off air filter housing and remove. – Pull air filter housing upwards out of brackets and remove.

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c ss

rrectness of i t to the co n f o r mat spec ion h re wit in

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– Push down protective cap in direction of -arrow- from solenoid switch.

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Prote cted by

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AG.

Rep. gr.27 - Starter, current supply, CCS

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cop yri gh t . Co py i

52

ht rig py Co t.

– Remove upper bolt -arrow- from starter.

thi sd o cu m en

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– Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove lower bolt -arrow- from starter. – Remove starter -B- from vehicle upwards. Installing Install in the reverse order of removal. When doing this, note the following: – Tighten threaded connections to specified torques ⇒ page 35 .

6.3.8

Vehicles with 2.0l diesel engine

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-

rrectness of i t to the co nform spec a t ion h re wit in t his

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t a itte riv du p r o nl f e ng

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d nte ir se o eo h t u ra a c ss

♦ Torque wrench -V.A.G 1332-

do c um en

ht rig py Co t.

Prote cted by c o py rig ht. C op yi

♦ Spring-type clip pliers -VAS 5024Aagen lksw Vo by

AG.

Carry out following procedures: Removing – Disconnect battery -A- ⇒ page 4 . 6. Starter B

Downloaded from www.Manualslib.com manuals search engine

53

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull engine cover panel upwards -arrows-.

– Disconnect connector -1-, release spring-type clip -2- with spring-type clip pliers -VAS 5024A- and pull off vacuum hose -3-.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Remove bolt of air filter housing -arrow-.

– Release locking lugs -arrows- and take off cover.

AG.

Downloaded from www.Manualslib.com manuals search engine

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

Rep. gr.27 - Starter, current supply, CCS

ht rig py Co t.

54

do c um en

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o te a itte ir v du p or nl f e ng

ility ab y li an pt ce

n AG. Volkswagen AG do es n wage ot g olks V ua by d ran ir se tee o h t or ac au s s

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull hose -arrow- off air filter housing and remove. – Pull air filter housing upwards out of brackets and remove.

– Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-.

rrectness of i t to the co nform spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e g n

– Slide protective cap in direction of -arrow- off solenoid switch.

ility ab y li an pt ce

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ht rig py Co t.

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AG.

Prote cted by c o py rig ht . C op yi

– Unclip wiring -1- from wiring retainer -2-.

6. Starter B

Downloaded from www.Manualslib.com manuals search engine

55

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove upper bolt -arrow- from starter.

– Remove lower bolt -arrow- from starter. un le pe rm itte d

Installing

ility ab y li an pt ce

– Remove starter -B- from vehicle upwards.

n AG. Volkswagen AG do es n wage ot g olks V y ua b d ran ise tee r o h t or u ac a ss

rrectness of i t to the co n f o r mat spec ion h re wit in

es, in part or in w l purpos hole ercia , is n m ot com

Install in the reverse order of removal. When doing this, note the following: – Tighten threaded connections to specified torques ⇒ page 35 .

6.3.9

Vehicles with 2.0l CR TDI engine

Special tools and workshop equipment required

ng

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AG.

Rep. gr.27 - Starter, current supply, CCS

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

56

ht rig py Co t.

♦ Torque wrench -V.A.G 1332-

thi sd o cu m en

r te o iva r rp fo

♦ Torque wrench -V.A.G 1331-

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Spring-type clip pliers -VAS 5024A-

Carry out following procedures: Removing – Disconnect battery -A- ⇒ page 4 . – Pull engine cover panel upwards -arrows-.

rrectness of i t to the co nform spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e g n

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h t u ra a c ss

ht rig py Co t.

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AG.

Prote cted by

cop yri gh t . Co py i

– Disconnect connector -1-, release spring-type clip -2- with spring-type clip pliers -VAS 5024A- and pull off vacuum hose -3-.

– Remove bolt of air filter housing -arrow-.

6. Starter B

Downloaded from www.Manualslib.com manuals search engine

57

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Release locking lugs -arrows- and take off cover.

– Pull hose -arrow- off air filter housing and remove. – Pull air filter housing upwards out of brackets and remove.

– Slide protective cap in direction of -arrow- off solenoid switch.

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t itte iva r du p or nl f e ng

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c ss

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AG.

Prote cted by

cop yri gh t . Co py i

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ht rig py Co t.

Rep. gr.27 - Starter, current supply, CCS

do c um en

58

rrectness of i t to the co nform spec a t ion h re wit in t his

– Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Unclip wiring -1- from wiring retainer -2-.

– Remove upper bolt -arrow- from starter.

Prote cted by c o py rig ht. C op yi

– Remove starter -B- from vehicle upwards. agen lksw Vo by

Installing

ht rig py Co t.

– Remove lower bolt -arrow- from starter.

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ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d nte ir se o eo h t u ra a c ss

Install in the reverse order of removal. When doing this, note the following: AG.

– Tighten threaded connections to specified torques ⇒ page 35 .

6. Starter B

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59

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

6.4

Removing and installing starter -B(manual gearbox)

6.4.1

Assembly overview - starter -B-

1 - Starter -B❑ Checking ⇒ page 13 2 - Battery positive wire con‐ nection to starter -B3 - Nut ❑ 15 Nm 4 - Bolt ❑ 75 Nm 5 - Protective cap 6 - Nut ❑ 23 Nm

n AG. Volkswagen AG do es n wage ot g olks V ua by d ran ir se tee o h t or ac au s s

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Not illustrated

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7 - Wiring retainer

♦ Air filter housing bolt to body: 10 Nm

6.4.2

Vehicles with 1.4l TSI engine

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AG.

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Rep. gr.27 - Starter, current supply, CCS

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60

thi sd o cu m en

Special tools and workshop equipment required

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Torque wrench -V.A.G 1331-

♦ Torque wrench -V.A.G 1332-

Carry out following procedures: Removing – Disconnect battery -A- ⇒ page 4 .

ility ab y li an pt ce

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm te o a itte ir v du p or nl f e ng

– Remove air filter housing ⇒ Engine;

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– Release and disconnect connector -1-.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Slide protective cap -1- off solenoid switch in direction of -arrow-.

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ht rig py Co t.

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AG.

Prote cted by c o py rig ht . C op yi

6. Starter B

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61

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

pe rm itte d

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran e tee ris o h t or u ac a ss

es, in part or in w l purpos hole ercia , is n m ot com

rrectness of i t to the co n f o r m spec atio h re n in wit

– Unscrew nut -1- from upper starter bolt and remove earth ca‐ ble -2-.

ility ab y li an pt ce

un le

– Unscrew nut -1- and remove positive wire -2- from connector thread of solenoid switch.

– Remove upper starter bolt behind from starter. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 .

ng

r te o iva r rp fo

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AG.

Prote cted b y c op yri gh t . Co py i

– Remove starter -B- -1- from vehicle downwards. Installing Install in the reverse order of removal. When doing this, note the following: – Tighten threaded connections to specified torques ⇒ page 60 .

6.4.3

Vehicles with 1.4 l petrol engine and 1.4/1.6 l FSI engine

Special tools and workshop equipment required

62

Rep. gr.27 - Starter, current supply, CCS

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ht rig py Co t.

– Remove lower starter bolt -2-.

thi sd o cu m en

– Unscrew nut -1- and remove wiring retainer -2- from lower starter bolt.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s ri o eo h t u ra a c ss

ht rig py Co t.

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thi sd o cu m en

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AG.

Prote cted by

♦ Spring-type clip pliers -VAS 5024A-

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♦ Torque wrench -V.A.G 1332-

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

un le

♦ Torque wrench -V.A.G 1331-

c o p yri gh t. C op yi

Carry out following procedures: Removing – Disconnect battery -A- ⇒ page 4 . – Loosen spring-type clip -1- using spring-type clip pliers -VAS 5024A- and remove bolt -2-. – Release hose -3- and pull it off the air filter housing.

6. Starter B

Downloaded from www.Manualslib.com manuals search engine

63

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull air filter housing upwards on right-hand side out of rubber AG. Volkswagen AG d agen oes mounting -arrow-. n lksw

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– Take air filter housing out of vehicle.

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Rep. gr.27 - Starter, current supply, CCS

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AG.

64

agen lksw Vo by

Prote cted by c o py rig h t . Co py i

– Unscrew earth wire from starter bolt -arrow-.

ht rig py Co t.

– Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-.

thi sd o cu m en

r te o iva r rp fo

– Slide protective cap in direction of -arrow- off solenoid switch.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

–

ility ab y li an pt ce

rrectness of i t to the co nform spec a t i h re o n in wit thi s

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o te a itte ir v du p or nl f e ng

–

AG. Volkswagen AG d agen oes ksw not l o V gu Unscrew starter bolt -arrow-. by ara d e n s ri o Remove noise uinsulation ⇒ General body repairs, exterior; tee o th ra Rep. gr. 50 .ss a c

– Remove nut -1- from lower starter bolt. – Remove wiring retainer -2-.

ht rig py Co t.

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c o p yri gh t. C op yi

AG.

Prote cted by

– Lower starter -B- out of vehicle.

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– Unscrew starter bolt -arrow-. Installing

Install in the reverse order of removal. When doing this, note the following: – Tighten threaded connections to specified torques ⇒ page 60 .

6.4.4

Vehicles with 1.6l petrol engine

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-

6. Starter B

Downloaded from www.Manualslib.com manuals search engine

65

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Torque wrench -V.A.G 1332-

Carry out following procedures:

n AG. Volkswagen AG do es n wage ot g olks V y ua db ran e Disconnect battery -A- ⇒ page 4 . ir s tee o h t or u ac a Push down protective cap in direction ss of -arrow- from solenoid

Removing

switch.

ility ab y li an pt ce

–

rrectness of i t to the co nform spec a t i h re o n in wit thi s

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm te o a itte ir v du p or nl f e ng

–

– Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-.

AG.

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Prote cted by c o py rig ht . C op yi

Rep. gr.27 - Starter, current supply, CCS

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66

do c um en

– Unscrew earth wire from starter bolt -arrow-.

– Remove nut -1- from lower starter bolt. – Remove wiring retainer -2-.

rrectness of i t to the co nform spec at i h re o n wit in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m m ot p r co erm o e t a itte v i r du p or nl f e g n

– Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 .

ility ab y li an pt ce

– Unscrew starter bolt

AG. Volkswagen AG d agen oes ksw not l o Golf Variant 2007 ➤ , Golf guVariant 2010 ➤ , Jetta 2005 ➤ yV b ara d e nte system - Edition 07.2010 Electrical is r o eo h ut ra a c s s -arrow-.

ht rig py Co t.

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AG.

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– Unscrew starter bolt -arrow-. – Remove starter -B- . Installing Install in the reverse order of removal. When doing this, note the following: – Tighten threaded connections to specified torques ⇒ page 60 .

6.4.5

Vehicles with 2.0l FSI engine

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-

6. Starter B

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67

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

Rep. gr.27 - Starter, current supply, CCS

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– Disconnect battery -A- ⇒ page 4 .

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68

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♦ Spring-type clip pliers -VAS 5024A-

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Loosen spring-type clip -arrow- from hose -1- using springtype clip pliers -VAS 5024A- .

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– Pull hose -1- off air filter housing.

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– Remove bolt of air filter housing -arrow-.

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– Open retainer -arrow- on front of air filter housing and remove line -1-.

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– Pull air filter housing upwards on right-hand side out of rubber mounting -arrow-. – Loosen spring-type clip -1- using spring-type clip pliers -VAS 5024A- .

6. Starter B

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69

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull hose -2- off connection. – Carefully lift up air filter housing out of vehicle as far as wiring allows.

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– Take air filter housing out of vehicle.

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– Disconnect connector -arrow- on rear of air filter housing.

– Slide protective cap in direction of -arrow- off solenoid switch.

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– Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-.

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– Unscrew starter bolt -arrow-. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 .

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– Unscrew earth wire from starter bolt -arrow-.

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– Remove nut -1- from lower starter bolt. – Remove wiring retainer -2-.

– Unscrew starter bolt -arrow-. – Lower starter -B- out of vehicle. Installing Install in the reverse order of removal. When doing this, note the following: – Tighten threaded connections to specified torques ⇒ page 60 .

6.4.6

Vehicles with 2.0l TFSI engine

Special tools and workshop equipment required

6. Starter B

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71

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Torque wrench -V.A.G 1331-

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♦ Spring-type clip pliers -VAS 5024A-

– Remove bolts -arrows-.

72

Rep. gr.27 - Starter, current supply, CCS

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AG.

– Disconnect battery -A- ⇒ page 4 .

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♦ Torque wrench -V.A.G 1332-

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Disconnect connector -arrow-.

– Loosen spring-type clips -arrow- using spring-type clip pliers VAS 5024A- .

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– Pull engine cover panel upwards -arrows-.

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6. Starter B

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– Unscrew earth wire from starter bolt -arrow-.

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– Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 .

– Remove nut -1- from lower starter bolt. – Remove wiring retainer -2-.

74

Rep. gr.27 - Starter, current supply, CCS

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– Unscrew starter bolt -arrow-.

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6.4.7

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⇒ page 60 .

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Vehicles with 2.5l petrol engine

Special tools and workshop equipment required

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Carry out following procedures: Removing – Disconnect battery -A- ⇒ page 4 . 6. Starter B

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75

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull engine cover panel upwards -arrows-.

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Rep. gr.27 - Starter, current supply, CCS

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76

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– Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-.

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– Push down protective cap in direction of -arrow- from solenoid switch.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Unscrew earth wire from starter bolt -arrow-.

– Unscrew starter bolt -arrow-. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 .

– Remove nut -1- from lower starter bolt. – Remove wiring retainer -2-.

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– Unscrew starter bolt -arrow-. – Remove starter -B- . Installing

Install in the reverse order of removal. When doing this, note the following: – Tighten threaded connections to specified torques ⇒ page 60 .

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6.4.8

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6. Starter B

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77

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Torque wrench -V.A.G 1331-

78

Rep. gr.27 - Starter, current supply, CCS

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– Pull engine cover upwards -arrows A- and forwards -arrow B-.

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– Disconnect battery -A- ⇒ page 4 .

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♦ Spring-type clip pliers -VAS 5024A-

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Disconnect connector -1- and release spring-type clip -2- us‐ ing spring type clip pliers -VAS 5024A- .

– Pull vacuum hose -arrow- off air filter housing.

– Remove bolt of air filter housing -arrow-.

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– Release locking lugs -arrows- and take off cover.

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6. Starter B

79

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull hose -arrow- off air filter housing and remove. – Pull air filter housing upwards out of brackets and remove.

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– Push down protective cap in direction of -arrow- from solenoid switch.

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– Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-.

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Rep. gr.27 - Starter, current supply, CCS

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80

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– Unscrew earth wire from starter bolt -arrow-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Unscrew starter bolt -arrow-. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 .

– Remove nut -1- from lower starter bolt.

Installing

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– Remove starter -B- .

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– Unscrew starter bolt -arrow-.

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– Remove wiring retainer -2-.

Install in the reverse order of removal. When doing this, note the following: – Tighten threaded connections to specified torques ⇒ page 60 .

6.4.9

Vehicles with 2.0l SDI engine

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6. Starter B

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thi sd o cu m en

Special tools and workshop equipment required

81

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Torque wrench -V.A.G 1332-

♦ Spring-type clip pliers -VAS 5024A-

Carry out following procedures: Removing – Disconnect battery -A- ⇒ page 4 . – Pull engine cover upwards -arrows A- and forwards -arrow B-.

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– Loosen spring-type clip -1- using spring-type clip pliers -VAS 5024A- and disconnect connector -2-. – Remove bolt -3-.

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Rep. gr.27 - Starter, current supply, CCS

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82

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull off vacuum hose -arrow-.

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– Push down protective cap in direction of -arrow- from solenoid switch.

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– Unscrew positive wire -1- and disconnect connector from ter‐ minal 50 -2-. agen lksw Vo by

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6. Starter B

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83

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Unscrew earth wire from starter bolt -arrow-.

– Unscrew starter bolt -arrow-. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 .

– Remove nut -1- from

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– Unscrew starter bolt -arrow-. – Remove starter -B- . Installing

Install in the reverse order of removal. When doing this, note the following: – Tighten threaded connections to specified torques ⇒ page 60 .

84

Rep. gr.27 - Starter, current supply, CCS

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AG.

Special tools and workshop equipment required

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Vehicles with 2.0l TSI engine

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6.4.10

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– Remove wiring retainer -2-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Torque wrench -V.A.G 1331-

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Carry out following procedures:

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♦ Spring-type clip pliers -VAS 5024A-

Removing – Disconnect battery -A- ⇒ page 4 . – Release and disconnect connector -1- and release spring-type clip -2- using spring-type clip pliers -VAS 5024- .

6. Starter B

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85

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– Release locking lugs -arrows- and take off cover.

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Rep. gr.27 - Starter, current supply, CCS

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AG.

– Slide protective cap -1- off solenoid switch in direction of -arrow-.

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– Pull air filter housing upwards out of its rubber mountings and remove from vehicle.

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– Remove bolt of air filter housing -arrow-.

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– Pull off hose -arrow- from air filter housing and remove from vehicle.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Release and disconnect terminal 50 connector -1-. – Unscrew nut -2- and remove positive lead -3- from solenoid switch.

– Remove upper bolt -arrow- from starter.

– Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 .

– Remove nut -1- from lower starter bolt.

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– Remove wiring retainer -2-.

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– Unscrew starter bolt -arrow-. – Lower starter -B- out of vehicle. Installing Install in the reverse order of removal. When doing this, note the following: – Tighten threaded connections to specified torques ⇒ page 60 .

6. Starter B

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87

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7

Alternator -CCaution

When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 .

7.1

Securing battery positive wire on alter‐ nator -CCaution

If the battery positive wire is not tightened to the specified tor‐ que, there is a risk of the following: ♦ The battery -A- will not be charged fully. ♦ Vehicle electrics or electronics fail completely (break‐ down). ♦ Danger of fires from sparks ♦ Damage to electronic components and control units due to excessive voltage – The specified torque for the nut -arrow- of the B+ wire is 15 Nm.

Caution

Always renew poly V-belt if it is defective. This will avoid pos‐ sible breakdowns or operating problems.

Carry out following procedures: – Crank engine at vibration damper/belt pulley using a socket. – Check poly V-belt for: ♦ Sub-surface cracks (cracks, core ruptures, cross sectional breaks)

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Rep. gr.27 - Starter, current supply, CCS

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♦ Fraying of cord strands

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Checking poly V-belt

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7.2

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Flank wear (material wear, frayed flanks, flank brittleness glassy flanks-, surface cracks) ♦ Traces of oil and grease

Checking alternator -C-

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7.3

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Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

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In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

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Procedure

– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system ♦ 27 - Starter, current supply ♦ Electrical components ♦ C - alternator

7. Alternator C

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89

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

Assembly overview

5 - Hexagon head flange bolts ❑ 40 Nm

7 - Hexagon head flange bolt ❑ 20 Nm 8 - Hexagon head flange bolts ❑ 40 Nm 9 - Protective cap 10 - Hexagon bolts with wash‐ er ❑ 2 Nm 11 - Protective cap for carbon brushes

12 - Voltage regulator -C1❑ Removing and installing ⇒ page 168 13 - Alternator -C❑ Removing and installing ⇒ page 91 ❑ Checking ⇒ page 89 ❑ Securing battery positive wire ⇒ page 88 ❑ Removing and installing poly V-belt pulley ⇒ page 163 14 - Poly V-belt ❑ Checking ⇒ page 88 ❑ Process ⇒ power unit; Rep. gr. 13 ❑ Removing and installing ⇒ Engine; Rep. gr. 13 15 - Hexagon bolt with washer and threaded element ❑ 2 Nm 16 - Poly V-belt tensioning element Not illustrated ♦ Nut of B+ wire on rear of alternator: 15 Nm ♦ Nut of wire holder on back of alternator : 3.2 Nm

90

Rep. gr.27 - Starter, current supply, CCS

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6 - Ancillary bracket ❑ For alternator -C- and air conditioner compres‐ sor ❑ Tightening sequence ⇒ Engine; Rep. gr. 13

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4 - Hexagon head flange bolts ❑ 20 Nm

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2 - Washer

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1 - Hexagon head flange bolt ❑ 60 Nm

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7.4.1

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7.4.2

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♦ Removing and installing ancillary bracket ⇒ Engine; Rep. gr. 13

Removing and installing alternator -C-

Special tools and workshop equipment required

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Carry out following procedures: Removing – Disconnect battery -A- ⇒ page 4 . Caution

When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 . – Disconnect DF wire connector -1- and pull off protective cap -2-.

7. Alternator C

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91

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Unscrew B+ wire -arrow- from alternator -C- . – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 . Caution

Before removing, mark the top side and direction of rotation of the poly V-belt. When installing, ensure correct fitting position and direction of rotation. If the belt is installed in the wrong position or against direction of rotation, the belt will be de‐ stroyed! – Mark direction of rotation of poly V-belt. – Release tension of poly V-belt by swivelling tensioning ele‐ ment in direction of -arrow- using a ring spanner.

– Lock tensioning element using locking pin -T10060A- .

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– Remove bolts of alternator -C- -arrows-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Unscrew wiring retainer -arrow- from alternator -C- . – Remove alternator -C- . Installing Install in the reverse order of removal. When doing this, note the following: Caution

♦ In order to avoid damage to cylinder block, note the dif‐ ferent bolt lengths for aluminium and grey cast iron cylin‐ der blocks when installing the ancillary bracket. ⇒ Engine; AG. Volkswagen AG d Rep. gr. 13 . agen oes ksw n ol yV

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♦ When fitting belt, ensure that poly V-belt seats correctly in pulleys! – Drive threaded sleeves -A- roughly 4 mm in -direction of arrow- out of alternator -C- housing.

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7. Alternator C

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93

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Secure wire holder -arrow- on back of alternator -C- in 9 o'clock position. – Tighten threaded connections to specified torques ⇒ page 90 . Caution

♦ When installing used poly V-belts observe the direction of rotation marked on removal! ♦ Before installing poly V-belt, make sure all assemblies ( alternator -C- / air conditioner compressor / vane pump) are firmly in position. ♦ When fitting poly V-belt, make sure it is properly seated on the pulleys. – Connect battery -A- ⇒ page 4 . Caution

Observe notes for battery pole terminal clamp bolt ⇒ page 1 . – Start engine and check belt is running correctly. AG. Volkswagen A agen ksw Vol y b ed ris ho t au ss

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– Switch off engine.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7.5

Alternator -C- 1.4l FSI engine

7.5.1

Assembly overview

1 - Hexagon bolt ❑ 40 Nm 2 - Washer 3 - Idler roller 4 - Washer 5 - Valve timing housing 6 - Securing nut battery posi‐ tive cable ❑ 15 Nm 7 - Cross-head screw ❑ 4.5 Nm 8 - Hexagon nut 9 - Washer 10 - Protective cap 11 - Cross-head screws ❑ 2 Nm 12 - Cross-head screw ❑ 2 Nm

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14 - Alternator -C❑ Removing and installing ⇒ page 96 ❑ Checking ⇒ page 89 ❑ Securing battery posi‐ tive wire ⇒ page 88 ❑ Removing and installing poly V-belt pulley ⇒ page 163

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20 - Hexagon head flange bolt ❑ 20 Nm + 1/4 turn (90 degrees) further

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18 - Tensioning element

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15 - Poly V-belt ❑ Checking ⇒ page 88 ❑ Removing and installing ⇒ Engine; Rep. gr. 13 ❑ Process ⇒ power unit; Rep. gr. 13

7. Alternator C

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95

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 21 - Spacer sleeve Not illustrated ♦ Nut of B+ wire on rear of alternator: 15 Nm ♦ Nut of wire holder on back of alternator : 3.2 Nm ♦ Poly V-belt pulley without freewheel: 65 Nm ♦ Poly V-belt pulley with freewheel: 80 Nm ♦ Removing and installing ancillary bracket ⇒ Engine; Rep. gr. 13

7.5.2

Removing and installing alternator -C-

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-

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– Disconnect battery -A- ⇒ page 4 .

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When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 .

96

Rep. gr.27 - Starter, current supply, CCS

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Carry out following procedures:

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– Remove upper bolt of alternator -C- -arrow-.

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– Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 .

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– Unscrew wiring retainer -1- and pull off protective cap -2-.

– Disconnect DF connector -1- and unscrew battery positive wire -2- from alternator -C- . Caution

Before removing, mark the top side and direction of rotation of the poly V-belt. When installing, ensure correct fitting position and direction of rotation. If the belt is installed in the wrong position or against direction of rotation, the belt will be de‐ stroyed! – Mark direction of rotation of poly V-belt.

7. Alternator C

Downloaded from www.Manualslib.com manuals search engine

97

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Release tension of poly V-belt by swivelling tensioning ele‐ ment in direction of -arrow- using an open-jaw spanner. – Lock tensioning element using locking pin -T10060A- . – Remove poly V-belt.

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– Remove bolts of air conditioner compressor -arrows-.

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– Release and disconnect connector -1-.

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98

Rep. gr.27 - Starter, current supply, CCS

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♦ Ensure that the hoses -2- are not stretched or kinked when

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– Unscrew third bolt -arrow- and remove air conditioner com‐ pressor from bracket.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove lower bolt of alternator -C- -arrow-. – Lower alternator -C- out of vehicle. Installing Install in the reverse order of removal. When doing this, note the following: Caution

♦ When installing used poly V-belts observe the direction of rotation marked on removal! ♦ Before installing poly V-belt, make sure all assemblies ( alternator -C- / air conditioner compressor / vane pump) are firmly in position. ♦ When fitting belt, ensure that poly V-belt seats correctlyein AG. Volkswagen AG d ag n oes pulleys! ksw not l o V by ed ris o h ut sa s mm in

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– Drive threaded sleeves -A- roughly 4 -direction of arrow- out of alternator -C- housing.

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– Secure wire holder -arrow- on back of alternator -C- in 9 o'clock position. – Tighten threaded connections to specified torques ⇒ page 95 . – Connect battery -A- ⇒ page 4 .

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– Start engine and check belt is running correctly.

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– Switch off engine.

7. Alternator C

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99

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7.6

Alternator -C- 1.4l, TSI engine

7.6.1

Assembly overview

1 - Multi-point socket head bolt ❑ 23 Nm 2 - Upper tensioning roller 3 - Valve timing housingswagen AG. 4

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6 - Cross-head screw ❑ 4.5 Nm 7 - Hexagon nut 8 - Washer 9 - Protective cap 10 - Cross-head screws ❑ 2 Nm 11 - Cross-head screw ❑ 2 Nm r te o iva r rp fo

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13 - Alternator -C❑ Removing and installing ⇒ page 90 ❑ Checking ⇒ page 89 ❑ Securing battery posi‐ tive wire ⇒ page 88 ❑ Removing and installing poly V-belt pulley ⇒ page 163

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12 - Voltage regulator -C1❑ Removing and installing ⇒ page 168

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14 - Poly V-belt ❑ Checking ⇒ page 88 ❑ Removing and installing ⇒ Engine; Rep. gr. 13 ❑ Poly V-belt routing ⇒ Engine; Rep. gr. 13 15 - Hexagon head flange bolts ❑ 23 Nm 16 - Centring sleeves ❑ Insert in bracket before installing air conditioner compressor 17 - Lower tensioning roller 18 - Bracket ❑ For tensioning element and air conditioner compressor

100

Rep. gr.27 - Starter, current supply, CCS

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 19 - Hexagon head flange bolt ❑ 45 Nm Not illustrated ♦ Nut of B+ wire on rear of alternator: 15 Nm ♦ Nut of wire holder on back of alternator : 3.2 Nm ♦ Poly V-belt pulley without freewheel: 65 Nm ♦ Poly V-belt pulley with freewheel: 80 Nm ♦ Removing and installing ancillary bracket ⇒ Engine; Rep. gr. 13

7.6.2

Removing and installing alternator -C-

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-

Carry out following procedures: Removing – Disconnect battery -A- ⇒ page 4 . Caution

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When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 .

– Release vacuum hose -arrow- and pull it off.

– Pull off engine cover upwards out of its rubber mountings -1and remove it forwards in -direction of arrow-. ht rig py Co t.

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7. Alternator C

Downloaded from www.Manualslib.com manuals search engine

101

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull activated charcoal filter -1- upwards out of fasteners -arrows-. – Place activated charcoal filter -1- with connected hoses to one side. – Remove poly V-belt ⇒ Engine; Rep. gr. 13 . – Unscrew bolts -arrows- and remove the upper belt tensioner from the vehicle.

– Remove upper bolt of alternator -C- -arrow-. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 ; Noise insulation .

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– Disconnect DF connector -1- and unscrew battery positive wire -2- from alternator -C- .

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102

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– Unscrew wiring

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– Release and disconnect connector -1-. – Unscrew third bolt -arrow- and remove air conditioner com‐ pressor from bracket.

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– Remove bolts of air conditioner compressor -arrows-.

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Note ♦ The hoses of the air conditioner compressor can remain con‐

nected.

♦ Suspend the air conditioner compressor -3- using a piece of

wire -1- at a suitable position under the vehicle until it is ready to be reinstalled.

♦ Ensure that the hoses -2- are not stretched or kinked when

doing this.

– Release and disconnect DF wire connector -1-. – Lever off protective cap -2-.

7. Alternator C

Downloaded from www.Manualslib.com manuals search engine

103

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove nut -1- and remove the battery positive wire, located beneath, from the connector thread of the alternator -C- . – Unscrew nut -3- and remove wiring retainer -2- from the alter‐ nator -C- . – Relieve tension on upper tensioning roller again.

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roller -1- from vehicle.

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♦ When fitting belt, ensure that poly V-belt seats correctly in pulleys! – Drive threaded sleeves -A- roughly 4 mm in -direction of arrow- out of alternator -C- housing.

104

Rep. gr.27 - Starter, current supply, CCS

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♦ Before installing poly V-belt, make sure all assemblies ( alternator -C- / air conditioner compressor / vane pump) are firmly in position.

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Install in the reverse order of removal. When doing this, note the following:

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Secure wire holder -arrow- on back of alternator -C- in 9 o'clock position.

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Before installing the air conditioner compressor, ensure that both centring sleeves ⇒ Item 16 (page 100) are inserted in the threa‐ ded holes (one above the other) of the bracket. – Tighten threaded connections to specified torques ⇒ page 100 . – Connect battery -A- ⇒ page 4 . Caution

Observe notes for battery pole terminal clamp bolt ⇒ page 1 . – Start engine and check belt is running correctly.

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7. Alternator C

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– Switch off engine.

105

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7.7

AG. Volkswagen AG d Alternator -C- 1.6l petrol engine agen oes n lksw

7.7.1

Assembly overview

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1 - Hexagon head flange bolt ❑ 23 Nm

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2 - Hexagon head flange bolts ❑ 23 Nm 3 - Bracket

4 - Hexagon flange nut

5 - Hexagon head flange bolts ❑ 52 Nm 6 - Protective cap

7 - Hexagon flange nut 8 - Cross-head screw ❑ 4.5 Nm

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13 - Voltage regulator -C1❑ Removing and installing ⇒ page 168 14 - Alternator -C❑ Removing and installing ⇒ page 107 ❑ Checking ⇒ page 89 ❑ Securing battery posi‐ tive wire ⇒ page 88 15 - Poly V-belt ❑ Checking ⇒ page 88 ❑ Removing and installing ⇒ Engine; Rep. gr. 13 ❑ Poly V-belt routing ⇒ Engine; Rep. gr. 13 16 - Ancillary bracket ❑ For alternator -C- and air conditioner compressor ❑ Tightening sequence ⇒ Engine; Rep. gr. 13 17 - Poly V-belt tensioning element 18 - Hexagon head flange bolt ❑ 23 Nm Not illustrated ♦ Nut of B+ wire on rear of alternator: 15 Nm ♦ Nut of wire holder on back of alternator : 3.2 Nm

106

Rep. gr.27 - Starter, current supply, CCS

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AG.

12 - Cross-head screw ❑ 2 Nm

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11 - Cross-head screws ❑ 2 Nm

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10 - Washer

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Poly V-belt pulley without freewheel: 65 Nm ♦ Poly V-belt pulley with freewheel: 80 Nm ♦ Removing and installing ancillary bracket ⇒ Engine; Rep. gr. 13

7.7.2

Removing and installing alternator -C-

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-

♦ Locking pin -T10060A-

– Disconnect battery -A- ⇒ page 4 .

AG.

When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 .

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– Pull engine cover panel upwards -arrows-.

7. Alternator C

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107

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Disconnect DF wire connector -1- and pull off protective cap -2-.

– Unscrew B+ wire -arrow- from alternator -C- . Caution

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– Lock tensioning element using locking pin -T10060A- . – Remove poly V-belt.

– Unclip coolant hose from hose bracket -1- and unscrew se‐ curing nut -2-.

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108

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– Release tension of poly V-belt by swivelling tensioning ele‐ ment in direction of -arrow- using an open-jaw spanner.

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– Mark direction of rotation of poly V-belt.

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s

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove bolts -arrows-. – Remove holder together with clamping element from vehicle.

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– Unscrew wiring retainer -arrow- from alternator -C- . – Remove alternator -C- . Installing

Install in the reverse order of removal. When doing this, note the following: Caution

♦ When installing used poly V-belts observe the direction of rotation marked on removal!

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♦ When fitting belt, ensure that poly V-belt seats correctly in pulleys!

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♦ Before installing poly V-belt, make sure all assemblies ( alternator -C- / air conditioner compressor) are firmly in position.

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– Remove bolts of alternator -C- -arrows-.

– Drive threaded sleeves -A- roughly 4 mm in -direction of arrow- out of alternator -C- housing.

7. Alternator C

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109

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Secure wire holder -arrow- on back of alternator -C- in 3 o'clock position.

Caution

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– Connect battery -A- ⇒ page 4 .

Observe notes for battery pole terminal clamp bolt ⇒ page 1 . – Start engine and check belt is running correctly.

1 - Hexagon bolt ❑ 40 Nm 2 - Washer 3 - Idler roller 4 - Washer 5 - Valve timing housing 6 - Hexagon flange nut 7 - Cross-head screw ❑ 4.5 Nm 8 - Hexagon nut 9 - Washer 10 - Protective cap 11 - Cross-head screws ❑ 2 Nm 12 - Cross-head screw ❑ 2 Nm 13 - Voltage regulator -C1❑ Removing and installing ⇒ page 168 14 - Alternator -C❑ Removing and installing ⇒ page 111 ❑ Checking ⇒ page 89 ❑ Securing battery posi‐ tive wire ⇒ page 88

15 - Poly V-belt ❑ Checking ⇒ page 88 ❑ Removing and installing ⇒ Engine; Rep. gr. 13 ❑ Poly V-belt routing ⇒ Engine; Rep. gr. 13

110

Rep. gr.27 - Starter, current supply, CCS

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Assembly overview

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7.8.1

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Alternator -C- 1.6l FSI engine

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– Switch off engine.

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– Tighten threaded connections to specified ⇒ page 106 .

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 16 - Hexagon head flange bolts ❑ 23 Nm 17 - Hexagon head flange bolts ❑ 25 Nm 18 - Tensioning element 19 - Bracket ❑ For tensioning element and air conditioner compressor 20 - Hexagon head flange bolt ❑ 20 Nm + 1/4 turn (90 degrees) further 21 - Spacer sleeve Not illustrated ♦ Nut of B+ wire on rear of alternator: 15 Nm ♦ Nut of wire holder on back of alternator : 3.2 Nm ♦ Poly V-belt pulley without freewheel: 65 Nm ♦ Poly V-belt pulley with freewheel: 80 Nm ♦ Removing and installing ancillary bracket ⇒ Engine; Rep. gr. 13

7.8.2

Removing and installing alternator -C-

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-

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♦ Locking pin -T10060-

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– Disconnect battery -A- ⇒ page 4 .

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Removing

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7. Alternator C

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111

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Caution

When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 . AG. Volkswagen AG d agen o – Remove

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– Disconnect DF connector -1- and unscrew battery positive wire -2- from alternator -C- . Caution

Before removing, mark the top side and direction of rotation of the poly V-belt. When installing, ensure correct fitting position and direction of rotation. If the belt is installed in the wrong position or against direction of rotation, the belt will be de‐ stroyed! – Mark direction of rotation of poly V-belt. – Release tension of poly V-belt by swivelling tensioning ele‐ ment in direction of -arrow- using an open-jaw spanner. – Lock tensioning element using locking pin -T10060- . – Remove poly V-belt. – Remove air conditioner compressor ⇒ Heating, ventilation, air conditioning system; Rep. gr. 87 .

112

Rep. gr.27 - Starter, current supply, CCS

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– Unscrew wiring retainer -1- and pull off protective cap -2-.

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– Remove Rep. gr. 50 .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove lower bolt of alternator -C- -arrow-. – Lower alternator -C- out of vehicle. Installing Install in the reverse order of removal. When doing this, note the following: Caution

♦ When installing used poly V-belts observe the direction of rotation marked on removal! ♦ Before installing poly V-belt, make sure all assemblies ( alternator -C- / air conditioner compressor / vane pump) are firmly in position. ♦ When fitting belt, ensure that poly V-belt seats correctly in pulleys! AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c ss

– Drive threaded sleeves -A- roughly 4 mm in -direction of arrow- out of alternator -C- housing.

– Tighten threaded connections to specified torques ⇒ page 110 . – Connect battery -A- ⇒ page 4 . Caution

Observe notes for battery pole terminal clamp bolt ⇒ page 1 .

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– Switch off engine.

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– Start engine and check belt is running correctly.

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– Secure wire holder -arrow- on back of alternator -C- in 9 o'clock position.

7. Alternator C

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113

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7.9

Alternator -C- 2.0l FSI engine

7.9.1

Assembly overview

1 - Hexagon head flange bolts ❑ 23 Nm 2 - Hexagon head flange bolts ❑ 23 Nm 3 - Transportation bracket 4 - Poly V-belt tensioning ele‐ ment

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5 - Ancillary bracket ❑ For alternator -C- and air conditioner compres‐ sor ❑ Tightening sequence ⇒ Engine; Rep. gr. 13

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6 - Hexagon head flange bolts ❑ 52 Nm

11 - Washer

13 - Cross-head screw ❑ 2 Nm

14 - Voltage regulator -C1❑ Removing and installing ⇒ page 168

15 - Alternator -C❑ Removing and installing ⇒ page 115 ❑ Checking ⇒ page 89 ❑ Securing battery positive wire ⇒ page 88 16 - Poly V-belt ❑ Checking ⇒ page 88 ❑ Removing and installing ⇒ Engine; Rep. gr. 13 ❑ Poly V-belt routing ⇒ Engine; Rep. gr. 13 Not illustrated ♦ Nut of B+ wire on rear of alternator: 15 Nm ♦ Nut of wire holder on back of alternator : 3.2 Nm ♦ Poly V-belt pulley without freewheel: 65 Nm

114

Rep. gr.27 - Starter, current supply, CCS

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12 - Cross-head screws ❑ 2 Nm

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10 - Hexagon nut

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8 - Hexagon flange nut

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7 - Protective cap

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Poly V-belt pulley with freewheel: 80 Nm ♦ Removing and installing ancillary bracket ⇒ Engine; Rep. gr. 13

7.9.2

Removing and installing alternator -C-

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331♦ Locking pin -T10060♦ Spring-type clip pliers -VAS 5024A-

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Carry out following procedures: Removing

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When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 .

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Caution

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– Disconnect battery -A- ⇒ page 4 .

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7. Alternator C

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115

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull engine cover panel upwards -arrows-.

– Unclip vacuum hose out of retainer -arrow-.

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Rep. gr.27 - Starter, current supply, CCS

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AG.

116

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– Pull hose -1- off air filter housing.

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– Loosen spring-type clip -arrow- from hose -1- using springtype clip pliers -VAS 5024A- .

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– Disconnect connector -arrow-.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Open retainer -arrow- on front of air filter housing and remove line -1-.

– Remove bolt of air filter housing -arrow-.

– Pull air filter housing upwards on right-hand side out of rubber mounting -arrow-.

– Pull hose -2- off connection. – Carefully lift up air filter housing out of vehicle as far as wiring allows.

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– Loosen spring-type clip -1- using spring-type clip pliers -VAS 5024 A- .

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7. Alternator C

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117

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Disconnect connector -arrow- on rear of air filter housing. – Take air filter housing out of vehicle. – Remove top part of intake manifold.

– Disconnect DF wire connector -1- and pull off protective cap -2-.

– Unscrew B+ wire -arrow- from alternator -C- .

Before removing, mark the top side and direction of rotation of the poly V-belt. When installing, ensure correct fitting position and direction of rotation. If the belt is installed in the wrong position or against direction of rotation, the belt will be de‐ stroyed! – Mark direction of rotation of poly V-belt. – Release tension of poly V-belt by swivelling tensioning ele‐ ment in direction of -arrow- using an open-jaw spanner.

AG.

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Rep. gr.27 - Starter, current supply, CCS

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118

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Caution

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Lock tensioning element using locking pin -T10060- . – Remove poly V-belt.

– Remove bolts of tensioning element -arrows-. – Remove tensioning element together with lifting eye -1- out of vehicle.

– Remove bolts of alternator -C- -arrows-.

– Unscrew wiring retainer -arrow- from alternator -C- . – Remove alternator -C- from vehicle. Install in the reverse order of removal. When doing this, note the following:

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7. Alternator C

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119

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Drive threaded sleeves -A- roughly 4 mm in -direction of arrow- out of alternator -C- housing.

– Secure wire holder -arrow- on back of alternator -C- in 12 o'clock position. – Tighten threaded connections to specified torques ⇒ page 114 . Caution

♦ When installing used poly V-belts observe the direction of rotation marked on removal! ♦ Before installing poly V-belt, make sure all assemblies ( alternator -C- / air conditioner compressor) are firmly in position. ♦ When fitting belt, ensure that poly V-belt seats correctly in pulleys! – Connect battery -A- ⇒ page 4 . Caution

Observe notes for battery pole terminal clamp bolt ⇒ pagen A1G.. Volkswagen AG

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Rep. gr.27 - Starter, current supply, CCS

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120

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– Switch off engine.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7.10

Alternator -C- 2.0l TFSI engine

7.10.1

Assembly overview

1 - Hexagon head flange bolts ❑ 23 Nm 2 - Hexagon head flange bolts ❑ 23 Nm 3 - Ancillary bracket ❑ For alternator -C- and air conditioner compres‐ sor ❑ Tightening sequence ⇒ Engine; Rep. gr. 13 4 - Hexagon head flange bolts ❑ 45 Nm 5 - Protective cap 6 - Hexagon flange nut 7 - Cross-head screw ❑ 4.5 Nm

10 - Cross-head screws ❑ 2 Nm

12 - Voltage regulator -C1❑ Removing and installing ⇒ page 168

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11 - Cross-head screw ❑ 2 Nm

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9 - Washer

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8 - Hexagon nut

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13 - Alternator -C❑ Removing and installing ⇒ page 122 ❑ Checking ⇒ page 89 ❑ Securing battery positive wire ⇒ page 88

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15 - Poly V-belt tensioning element

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14 - Poly V-belt ❑ Checking ⇒ page 88 ❑ Removing and installing ⇒ Engine; Rep. gr. 13 ❑ Poly V-belt routing ⇒ Engine; Rep. gr. 13

♦ Nut of B+ wire on rear of alternator: 15 Nm ♦ Nut of wire holder on back of alternator : 3.2 Nm ♦ Poly V-belt pulley without freewheel: 65 Nm ♦ Poly V-belt pulley with freewheel: 80 Nm

7. Alternator C

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121

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Removing and installing ancillary bracket ⇒ Engine; Rep. gr. 13

7.10.2

Removing and installing alternator -C-

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331♦ Spring-type clip pliers -VAS 5024 A♦ Locking pin -T10060-

Carry out following procedures: Removing

– Disconnect battery -A- ⇒ page 4 . Caution

When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 .

AG.

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Rep. gr.27 - Starter, current supply, CCS

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122

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– Remove bolts -arrows-.

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– Disconnect connector -arrow-.

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– Loosen spring-type clips -arrow- using spring-type clip pliers VAS 5024 A- . Prote cted by

– Pull engine cover panel upwards -arrows-.

7. Alternator C

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123

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Note ♦ All hose connections of charge air system are secured with

spring-type clips or push-on connectors. The following points must be observed for push-on connectors:

♦ Release push-on connection by pulling securing ring -arrow-. ♦ Pull off hose/pipe without tools.

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– Disconnect plug connector -arrow-.

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– Loosen spring-type clip -arrow- using spring-type clip pliers VAS 5024 A- .

– Mark direction of rotation of poly V-belt.

124

Rep. gr.27 - Starter, current supply, CCS

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Before removing, mark the top side and direction of rotation of the poly V-belt. When installing, ensure correct fitting position and direction of rotation. If the belt is installed in the wrong position or against direction of rotation, the belt will be de‐ stroyed!

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Caution

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– Remove connecting pipe between charge air cooler and tur‐ bocharger.

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– Remove hose from vehicle.

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– Remove bolts -arrows-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Release tension on poly V-belt by levering back tensioning el‐ ement in -direction of arrow- using an open-jaw spanner and lock tensioning element with locking pin -T10060- . – Remove poly V-belt.

– Loosen the threaded connections of the coolant pipe -arrows-. Note

The coolant pipe can remain installed. It will have to be loosened in order to be able to remove the alternator -C- .

– Remove bolts of alternator -C- -arrows-.

– Disconnect DF wire connector -1- and pull off protective cap -2-.

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7. Alternator C

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125

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Unscrew B+ wire -arrow- from alternator -C- .

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– Unscrew wiring retainer -arrow- from alternator -C- . Installing

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– Remove alternator -C- from vehicle.

Install in the reverse order of removal. When doing this, note the following: Caution

♦ When installing used poly V-belts observe the direction of rotation marked on removal! ♦ Before installing poly V-belt, make sure all assemblies ( alternator -C- / air conditioner compressor) are firmly in position.

Rep. gr.27 - Starter, current supply, CCS

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AG.

126

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– Secure wire holder -arrow- on back of alternator -C- in 9 o'clock position.

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– Drive threaded sleeves -A- roughly 4 mm in -direction of arrow- out of alternator -C- housing.

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♦ When fitting belt, ensure that poly V-belt seats correctly in pulleys!

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Note

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♦ Push on hose or pipe without tools. ♦ Ensure that locking lugs are securely engaged -arrow-

– Connect battery -A- ⇒ page 4 . Caution

Observe notes for battery pole terminal clamp bolt ⇒ page 1 . – Start engine and check belt is running correctly. – Switch off engine.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Tighten threaded connections to specified torques ⇒ page 121 .

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♦

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7. Alternator C

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127

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7.11

Alternator -C- 2.5l petrol engine

7.11.1

Assembly overview

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2 - Multi-point socket head bolt ❑ 25 Nm 3 - Multi-point socket head bolt ❑ 25 Nm 4 - Hexagon socket head bolts ❑ 25 Nm ❑ Qty. 4 5 - Protective cap for alternator -C6 - Cross-head screws ❑ 2 Nm 7 - Protective cap for carbon brushes

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9 - Alternator -C❑ Removing and installing ⇒ page 132 ❑ Checking ⇒ page 89 ❑ Securing battery posi‐ tive wire ⇒ page 88 ❑ Removing and installing poly V-belt pulley ⇒ page 163

10 - Poly V-belt ❑ Checking ⇒ page 88 ❑ Removing and installing ⇒ Engine; Rep. gr. 13 ❑ Process ⇒ power unit; Rep. gr. 13 11 - Hexagon head flange bolts ❑ 25 Nm ❑ Qty. 2 Not illustrated ♦ Nut of B+ wire on rear of alternator: 15 Nm ♦ Nut of wire holder on back of alternator : 3.2 Nm ♦ Poly V-belt pulley without freewheel: 65 Nm ♦ Poly V-belt pulley with freewheel: 80 Nm ♦ Removing and installing ancillary bracket ⇒ Engine; Rep. gr. 13

128

Rep. gr.27 - Starter, current supply, CCS

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8 - Voltage regulator -C1❑ Removing and installing ⇒ page 168

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7.11.2

Removing and installing alternator -C-

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-

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– Pull off engine cover upwards and forwards.

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es, in part or in w l purpos hole ercia , is n m m ot p r co erm o e t a itte v i r du p or nl f e g n

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When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 .

– Place lock carrier in service position ⇒ General body repairs, exterior; Rep. gr. 50 . – Remove poly V-belt ⇒ Engine; Rep. gr. 13 .

– Disconnect DF wire connector -1- and pull off protective cap -2-. ht rig py Co t.

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7. Alternator C

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129

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Unscrew B+ wire -arrow- from alternator -C- . Caution

Before removing, mark the top side and direction of rotation of the poly V-belt. When installing, ensure correct fitting position and direction of rotation. If the belt is installed in the wrong position or against direction of rotation, the belt will be de‐ stroyed! – Remove the upper idler wheel, lower idler wheel and the poly V-belt tensioner for alternator -C- and coolant pump ⇒ Engine; . Volkswagen AG Rep. gr. 13 . gen AG does swa

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-C- -arrows-.

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– Take alternator -C- out upwards. Installing

Install in the reverse order of removal. When doing this, note the following: Caution

♦ When installing used poly V-belts observe the direction of rotation marked on removal!

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♦ Before installing poly V-belt, make sure all assemblies ( alternator -C- / air conditioner compressor) are firmly in position. AG.

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♦ When fitting belt, ensure that poly V-belt seats correctly in pulleys! – Drive threaded sleeves -A- roughly 4 mm in direction of arrow out of alternator -C- housing.

130

Rep. gr.27 - Starter, current supply, CCS

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rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Unscrew wiring retainer from alternator -C- -arrow-.

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– Remove

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Secure wire holder -arrow- on back of alternator -C- in 9 o'clock position. – Tighten threaded connections to specified torques ⇒ page 128 . – Connect battery -A- ⇒ page 4 . Caution

Observe notes for battery pole terminal clamp bolt ⇒ page 1 . – Start engine and check belt is running correctly. – Switch off engine.

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7.12.1

Alternator -C- 1.9l diesel engine urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t a itte iv du pr r o nl f e ng

7.12

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Assembly overview

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1 - Hexagon head flange bolts ❑ 20 Nm 2 - Poly V-belt tensioning ele‐ ment 3 - Hexagon head flange bolts ❑ 20 Nm

AG.

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7 - Hexagon bolt with washer and threaded element ❑ 2 Nm

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6 - Hexagon head flange bolts ❑ 40 Nm

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5 - Hexagon head flange bolts ❑ 40 Nm

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4 - Ancillary bracket ❑ For alternator -C- and air conditioner compres‐ sor ❑ Tightening sequence ⇒ Engine; Rep. gr. 13

8 - Protective cap for alternator -C9 - Cross-head screws ❑ 2 Nm 10 - Protective cap for carbon brushes 11 - Voltage regulator -C1❑ Removing and installing ⇒ page 168 12 - Alternator -C❑ Removing and installing ⇒ page 132 ❑ Checking ⇒ page 89

7. Alternator C

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131

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ❑ Securing battery positive wire ⇒ page 88 13 - Poly V-belt ❑ Checking ⇒ page 88 ❑ Removing and installing ⇒ Engine; Rep. gr. 13 ❑ Poly V-belt routing ⇒ Engine; Rep. gr. 13 Not illustrated ♦ Nut of B+ wire on rear of alternator: 15 Nm ♦ Nut of wire holder on back of alternator : 3.2 Nm ♦ Poly V-belt pulley without freewheel: 65 Nm ♦ Poly V-belt pulley with freewheel: 80 Nm ♦ Removing and installing ancillary bracket ⇒ Engine; Rep. gr. AG. Volkswagen AG do agen 13 es n lksw

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Removing – Disconnect battery -A- ⇒ page 4 . Caution

When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 .

132

Rep. gr.27 - Starter, current supply, CCS

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AG.

cop yri gh t . Co py i

Carry out following procedures:

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♦ Locking pin -T10060-

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♦ Torque wrench -V.A.G 1331-

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Special tools and workshop equipment

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7.12.2

ot g ua ran tee or ac

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull engine cover off upwards -arrows A- and forwards -arrow B-.

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t a itte riv du p r o nl f e ng

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AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c Note ss

♦ All hose connections of charge air system are secured with

♦ Release push-on connection by pulling securing ring -arrow-. ♦ Pull off hose/pipe without tools.

– Separate push-on connectors -1-. – Unclip fuel hoses -2- and remove charge air hose.

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– Pull off vacuum hose -1-.

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spring-type clips or push-on connectors. The following points must be observed for push-on connectors:

– Disconnect connector -2-. – Remove bolt -3-.

7. Alternator C

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133

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Unscrew bolt -arrow-. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 .

– Remove bolt of charge air pipe -arrow-.

– Separate push-fit coupling of charge air pipe -arrow-.

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– Disconnect DF wire connector -1- and pull off protective cap -2-.

AG.

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Rep. gr.27 - Starter, current supply, CCS

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134

rrectness of i t to the co nform spec at i h re o n wit in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m m ot p r co erm o e t a itte v i r du p or nl f e g n

– Remove charge air pipe upwards.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Unscrew B+ wire -arrow- from alternator -C- . – Pull fuel filter out of bracket and place to one side. When doing this, the fuel hoses can remain connected. Caution

Before removing, mark the top side and direction of rotation of the poly V-belt. When installing, ensure correct fitting position and direction of rotation. If the belt is installed in the wrong position or against direction of rotation, the belt will be de‐ stroyed! – Mark direction of rotation of poly V-belt. – Release tension of poly V-belt by swivelling tensioning ele‐ ment in direction of -arrow- using an open-jaw spanner.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Lock tensioning element using locking pin -T10060- . – Remove poly V-belt.

– Remove bolts of alternator -C- -arrows-.

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urposes, in part or in wh ole, cial p is n mer m ot p r co erm o te a itte ir v du p or nl f e ng

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7. Alternator C

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135

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Unscrew wiring retainer from alternator -C- -arrow-. – Remove alternator -C- . Installing Install in the reverse order of removal. When doing this, note the following: Caution

♦ When installing used poly V-belts observe the direction of . Volkswagen AG rotation marked on removal! gen AG does swa k Vol

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♦ When fitting belt, ensure that poly V-belt seats correctly in pulleys!

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AG.

Rep. gr.27 - Starter, current supply, CCS

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136

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– Secure wire holder -arrow- on back of alternator -C- in 9 o'clock position.

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– Drive threaded sleeves -A- roughly 4 mm in -direction of arrow- out of alternator -C- housing.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Note ♦ All hose connections of charge air system are secured with

spring-type clips or push-on connectors. The following points must be observed for push-on connectors:

♦ Push on hose or pipe without tools. ♦ Ensure that locking lugs are securely engaged -arrow– Tighten threaded connections to specified torques ⇒ page 131 . – Connect battery -A- ⇒ page 4 . Caution

Observe notes for battery pole terminal clamp bolt ⇒ page 1 . – Start engine and check belt is running correctly. – Switch off engine.

rrectness of i t to the co nform spec a t ion h re wit in t his

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7. Alternator C

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137

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7.13

Alternator -C- 1.9l diesel engine with diesel particle filter

7.13.1

Assembly overview

1 - Hexagon head flange bolts ❑ 20 Nm 2 - Poly V-belt tensioning ele‐ ment

pe rm itte d es, in part or in w l purpos hole ercia , is n m ot com

ng

r te o iva r rp fo

11 - Voltage regulator -C1❑ Removing and installing ⇒ page 168 12 - Alternator -C❑ Removing and installing ⇒ page 139 ❑ Checking ⇒ page 89 ❑ Securing battery positive wire ⇒ page 88 ❑ Removing and installing poly V-belt pulley ⇒ page 163 13 - Poly V-belt ❑ Checking ⇒ page 88 ❑ Removing and installing ⇒ Engine; Rep. gr. 13 ❑ Poly V-belt routing ⇒ Engine; Rep. gr. 13

138

Rep. gr.27 - Starter, current supply, CCS

Downloaded from www.Manualslib.com manuals search engine

AG.

10 - Protective cap for carbon brushes

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9 - Cross-head screws ❑ 2 Nm

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8 - Protective cap for alternator -C-

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7 - Hexagon bolt with washer and threaded element ❑ 2 Nm

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6 - Hexagon head flange bolts ❑ Observe specified tight‐ ening sequence ⇒ En‐ gine; Rep. gr. 13 ❑ 40 Nm

rrectness of i t to the co n f o r m spec atio h re n in wit

5 - Hexagon head flange bolts ❑ Observe specified tight‐ ening sequence ⇒ En‐ gine; Rep. gr. 13 ❑ 40 Nm

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4 - Ancillary bracket ❑ For alternator -C- and air conditioner compres‐ sor ❑ Observe specified tight‐ ening sequence ⇒ En‐ gine; Rep. gr. 13

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3 - Hexagon head flange bolts ❑ 20 Nm

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Not illustrated ♦ Nut of B+ wire on rear of alternator: 15 Nm ♦ Nut of wire clip on back of alternator : 3.2 Nm ♦ Poly V-belt pulley without freewheel: 65 Nm ♦ Poly V-belt pulley with freewheel: 80 Nm ♦ Removing and installing ancillary bracket ⇒ Engine; Rep. gr. 13 .

7.13.2

Removing and installing alternator -C-

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-

♦ Locking pin -T10060A-

Carry out following procedures: Removing

– Disconnect battery -A- ⇒ page 4 . Caution

When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 .

rrectness of i t to the co nform spec at i h re o n wit in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m m ot p r co erm o e t a itte v i r du p or nl f e ng

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AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r o eo h t u ra a c ss

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7. Alternator C

Downloaded from www.Manualslib.com manuals search engine

139

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – First pull engine cover upwards -arrows A- and then forwards -arrow B-.

Note ♦ All hose connections of charge air system are secured with

spring-type clips or push-on connectors. The following points must be observed for push-on connectors:

♦ Release push-on connection by pulling securing ring -arrow-. ♦ Pull off hose/pipe without tools.

ility ab y li an pt ce

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–

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Rep. gr.27 - Starter, current supply, CCS

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140

thi sd o cu m en

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– Disconnect DF wire connector -1- and pull off protective cap -2-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Unscrew B+ wire -arrow- from alternator -C- . – Pull fuel filter out of bracket and place to one side. When doing this, the fuel hoses can remain connected. Caution

Before removing, mark the top side and direction of rotation of the poly V-belt. When installing, ensure correct fitting position and direction of rotation. If the belt is installed in the wrong position or against direction of rotation, the belt will be de‐ stroyed! – Mark direction of rotation of poly V-belt. – Release tension of poly V-belt by swivelling tensioning ele‐ ment in direction of -arrow- using an open-jaw spanner.

– Lock tensioning element using locking pin -T10060A- .

n AG. Volkswagen AG do es n wage ot g olks V ua by d ran ir se tee o h t or ac au s s

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pe rm itte d

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– Remove poly V-belt.

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– Remove bolts of alternator -C- -arrows-.

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7. Alternator C

Downloaded from www.Manualslib.com manuals search engine

141

n AG. Volkswagen AG do es n wage ot g olks V y ua d,bGolf Variant 2010 ➤ , Jetta 2005 ➤ Golf Variant 2007 ➤ ran e is tee r o h - Edition 07.2010 Electrical system t or u ac a ss pe rm itte d

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ility ab y li an pt ce

– Unscrew wiring retainer from alternator -C- -arrow-.

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Installing

es, in part or in w l purpos hole ercia , is n m ot com

– Remove alternator -C- . Install in the reverse order of removal. When doing this, note the following: Caution

♦ In order to avoid damage to cylinder block and ancillaries bracket, adhere strictly to the tightening sequence for the ancillaries bracket ⇒ Engine; Rep. gr. 13 . ♦ When installing used poly V-belts observe the direction of rotation marked on removal! r te o iva r rp fo

ng

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– Drive threaded sleeves -A- roughly 4 mm in -direction of arrow- out of alternator -C- housing.

– Secure wire holder -arrow- on back of alternator -C- in 9 o'clock position.

142

Rep. gr.27 - Starter, current supply, CCS

Downloaded from www.Manualslib.com manuals search engine

ht rig py Co t.

♦ When fitting belt, ensure that poly V-belt seats correctly in pulleys!

thi sd o cu m en

♦ Before installing poly V-belt, make sure all assemblies ( alternator -C- / air conditioner compressor) are firmly in position.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Note ♦ All hose connections of charge air system are secured with

spring-type clips or push-on connectors. The following points must be observed for push-on connectors:

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♦ Push on hose or pipe without tools.

⇒ page 138 .

– Connect battery -A- ⇒ page 4 .

Observe notes for battery pole terminal clamp bolt ⇒ page 1 . – Start engine and check belt is running correctly.

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– Switch off engine.

c o p yri gh t. C op yi

7. Alternator C

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Caution

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–

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♦

143

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7.14

Alternator -C- 2.0l SDI engine

7.14.1

Assembly overview

8 - Protective cap 9 - Voltage regulator -C1❑ Removing and installing ⇒ page 168

10 - Alternator -C❑ Removing and installing ⇒ page 145 ❑ Checking ⇒ page 89 ❑ Securing battery positive wire ⇒ page 88 ❑ Removing and installing poly V-belt pulley ⇒ page 163 11 - Poly V-belt ❑ Checking ⇒ page 88 ❑ Removing and installing ⇒ Engine; Rep. gr. 13 ❑ Process for poly V-belt ⇒ Engine; Rep. gr. 13 Not illustrated ♦ Nut of B+ wire on rear of alternator: 15 Nm ♦ Nut of wire holder on back of alternator : 3.2 Nm ♦ Poly V-belt pulley without freewheel: 65 Nm

144

Rep. gr.27 - Starter, current supply, CCS

Downloaded from www.Manualslib.com manuals search engine

AG.

7 - Cross-head screws ❑ 2 Nm

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6 - Hexagon head flange bolts ❑ 40 Nm ❑ Observe specified tight‐ ening sequence ⇒ En‐ gine; Rep. gr. 13

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5 - Hexagon head flange bolts ❑ 40 Nm ❑ Observe specified tight‐ ening sequence ⇒ En‐ gine; Rep. gr. 13

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4 - Ancillary bracket ❑ For alternator -C- and air conditioner compres‐ sor ❑ Observe specified tight‐ ening sequence ⇒ En‐ gine; Rep. gr. 13

ility ab y li an pt ce

3 - Hexagon head flange bolts ❑ 20 Nm

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e g n

2 - Poly V-belt tensioning ele‐ ment

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1 - Hexagon head flange bolts ❑ 20 Nm

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Poly V-belt pulley with freewheel: 80 Nm ♦ Removing and installing ancillary bracket ⇒ Engine; Rep. gr. 13

7.14.2

Removing and installing alternator -C-

Special tools and workshop equipment required

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d nte ir se o eo h t u ra a c ss

♦ Torque wrench -V.A.G 1331-

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AG.

Removing

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Carry out following procedures:

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ility ab y li an pt ce

♦ Locking pin -T10060A-

– Disconnect battery -A- ⇒ page 4 . Caution

When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 . – Pull engine cover upwards -arrows A- and forwards -arrow B-.

7. Alternator C

Downloaded from www.Manualslib.com manuals search engine

145

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r o eo h t u ra a c ss

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– Disconnect DF wire connector -1- and pull off protective cap -2-.

– Unscrew B+ wire -arrow- from alternator -C- . – Pull fuel filter out of bracket and place to one side. When doing this, the fuel hoses can remain connected. Caution

Prote cted by

– Remove poly V-belt.

146

Rep. gr.27 - Starter, current supply, CCS

Downloaded from www.Manualslib.com manuals search engine

AG.

– Lock tensioning element using locking pin -T10060A- .

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– Release tension of poly V-belt by swivelling tensioning ele‐ ment in direction of -arrow- using an open-jaw spanner.

ht rig py Co t.

ng

– Mark direction of rotation of poly V-belt.

thi sd o cu m en

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Before removing, mark the top side and direction of rotation of the poly V-belt. When installing, ensure correct fitting position and direction of rotation. If the belt is installed in the wrong position or against direction of rotation, the belt will be de‐ stroyed!

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove bolts of alternator -C- -arrows-.

– Unscrew wiring retainer -arrow- from alternator -C- . – Remove alternator -C- . Installing Install in the reverse order of removal. When doing this, note the following:

– Drive threaded sleeves -A- roughly 4 mm in -direction of arrow- out of alternator -C- housing. Caution

♦ When installing used poly V-belts observe the direction of rotation marked on removal!

rrectness of i t to the co nform spec a t i h re o n in wit thi s

♦ Before installing poly V-belt, make sure all assemblies ( alternator -C- / air conditioner compressor / vane pump) are firmly in position.

ility ab y li an pt ce

♦ When fitting belt, ensure that poly V-belt seats correctly in pulleys! – Tighten threaded connections to specified torques ⇒ page 144 . – Connect battery -A- ⇒ page 4 . Caution

Observe notes for battery pole terminal clamp bolt ⇒ page 1 . – Start engine and check belt is running correctly. ht rig py Co t.

– Switch off engine.

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♦

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7. Alternator C

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147

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7.15

Alternator -C- 2.0l diesel engine

7.15.1

Assembly overview

1 - Hexagon head flange bolts ❑ 20 Nm 2 - Poly V-belt tensioning ele‐ ment 3 - Hexagon head flange bolts ❑ 20 Nm

8 - Protective cap 9 - Voltage regulator -C1❑ Removing and installing ⇒ page 168 10 - Alternator -C❑ Removing and installing ⇒ page 148 ❑ Checking ⇒ page 89 ❑ Securing battery posi‐ tive wire ⇒ page 88

11 - Poly V-belt ❑ Checking ⇒ page 88 ❑ Process for poly V-belt ⇒ Engine; Rep. gr. 13

Prote cted by

♦ Poly V-belt pulley without freewheel: 65 Nm ♦ Poly V-belt pulley with freewheel: 80 Nm ♦ Removing and installing ancillary bracket ⇒ Engine; Rep. gr. 13

7.15.2

Removing and installing alternator -C-

Special tools and workshop equipment required

148

Rep. gr.27 - Starter, current supply, CCS

Downloaded from www.Manualslib.com manuals search engine

AG.

♦ Nut of wire holder on back of alternator : 3.2 Nm

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♦ Nut of B+ wire on rear of alternator: 15 Nm

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Not illustrated

rrectness of i t to the co nform spec atio h re n wit i n thi sd o c um en

7 - Cross-head screws ❑ 2 Nm

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6 - Hexagon head flange bolts ❑ 40 Nm

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5 - Hexagon head flange bolts ❑ 40 Nm

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4 - Ancillary bracket ❑ For alternator -C- and air conditioner compres‐ sor ❑ Tightening sequence ⇒ Engine; Rep. gr. 13

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Torque wrench -V.A.G 1331-

♦ Locking pin -T10060-

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra ⇒s apage 4. c s

Carry out following procedures: Removing

Caution

rrectness of i t to the co nform spec a t i h re o n in wit thi s

When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 .

ility ab y li an pt ce

– Pull engine cover panel upwards -arrows-.

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urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e ng

– Disconnect battery -A-

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7. Alternator C

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149

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull off vacuum hoses -arrows-.

– Remove bolts -arrows-.

– Disconnect DF wire connector -1- and pull off protective cap -2-.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm te o a itte ir v du p or nl f e ng

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– Unscrew B+ wire -arrow- from alternator -C- . – Pull fuel filter out of bracket and place to one side. When doing this, the fuel hoses can remain connected. Caution

Before removing, mark the top side and direction of rotation of the poly V-belt. When installing, ensure correct fitting position and direction of rotation. If the belt is installed in the wrong position or against direction of rotation, the belt will be de‐ stroyed!

AG.

Downloaded from www.Manualslib.com manuals search engine

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Rep. gr.27 - Starter, current supply, CCS

ht rig py Co t.

150

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– Mark direction of rotation of poly V-belt.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Release tension of poly V-belt by swivelling tensioning ele‐ ment in direction of -arrow- using an open-jaw spanner.

– Lock tensioning element using locking pin -T10060- . – Remove poly V-belt.

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e ng

ility ab y li an pt ce

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rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Remove bolts of alternator -C- -arrows-.

– Unscrew wiring retainer -arrow- from alternator -C- . Installing

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– Remove alternator -C- . ht rig py Co t.

Install in the reverse order of removal. When doing this, note the following: agen lksw Vo by

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Caution

♦ When installing used poly V-belts observe the direction of rotation marked on removal! ♦ Before installing poly V-belt, make sure all assemblies ( alternator -C- / air conditioner compressor) are firmly in position. ♦ When fitting belt, ensure that poly V-belt seats correctly in pulleys!

7. Alternator C

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151

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Drive threaded sleeves -A- roughly 4 mm in -direction of arrow- out of alternator -C- housing.

– Secure wire holder -arrow- on back of alternator -C- in 9 o'clock position. – Tighten threaded connections to specified torques ⇒ page 148 . – Connect battery -A- ⇒ page 4 . Caution

Observe notes for battery pole terminal clamp bolt ⇒ page 1 . – Start engine and check belt is running correctly.

Downloaded from www.Manualslib.com manuals search engine

AG.

Rep. gr.27 - Starter, current supply, CCS

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152

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ht rig py Co t.

– Switch off engine.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7.16

Alternator -C- 2.0l CR diesel engine

7.16.1

Assembly overview

1 - Hexagon bolt with washer and threaded element ❑ 2 Nm 2 - Protective cap for alternator -C3 - Cross-head screws ❑ 2 Nm 4 - Protective cap for carbon brushes 5 - Voltage regulator -C1❑ Removing and installing ⇒ page 168 6 - Alternator -C❑ Removing and installing ⇒ page 153 ❑ Checking ⇒ page 89 ❑ Securing battery posi‐ tive wire ⇒ page 88 7 - Poly V-belt ❑ Removing and installing ⇒ Engine; Rep. gr. 13 ❑ Poly V-belt routing ⇒ Engine; Rep. gr. 13 n AG. Volkswagen AG do es n wage ot g ❑ Checking ⇒ page 88 y Volks u b ed

ara nte e

or ac

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Not illustrated

♦ Nut of B+ wire on rear of alternator: 15 Nm ♦ Nut of wire holder on back of alternator : 3.2 Nm ♦ Poly V-belt pulley without freewheel: 65 Nm ♦ Poly V-belt pulley with freewheel: 80 Nm ♦ Removing and installing ancillary bracket ⇒ Engine; Rep. gr. 13

7.16.2

Removing and installing alternator -C-

Special tools and workshop equipment required

do c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t a itte iv du pr r o nl f e ng

ility ab y li an pt ce

ris 8 - Hexagon head flange hobolts ut a ❑ 20 Nm ss

ht rig py Co t.

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AG.

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7. Alternator C

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153

. Volkswage

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urposes, in part or in wh ole, cial p is n mer m ot p r co erm o te a itte ir v du p or nl f e ng

♦ Torque wrench -V.A.G 1331-

an tee or ac

e ris tho u a ss

Carry out following procedures: Removing

– Disconnect battery -A- ⇒ page 4 .

Caution

Before removing, mark the top side and direction of rotation of the poly V-belt. When installing, ensure correct fitting position and direction of rotation. If the belt is installed in the wrong position or against direction of rotation, the belt will be de‐ stroyed! – Remove poly V-belt ⇒ Engine; Rep. gr. 13 . – Release and disconnect connector -1-.

154

Rep. gr.27 - Starter, current supply, CCS

Downloaded from www.Manualslib.com manuals search engine

AG.

– Place lock carrier in service position ⇒ General body repairs, exterior; Rep. gr. 50 .

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– Holding engine cover at corners -arrows-, jerk it upwards out of attachment points.

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When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 .

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Caution

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compressor -arrows-.

nected.

rrectness of i t to the co nform spec a t ion h re wit in t his

♦ The hoses of the air conditioner compressor can remain con‐ ♦ Until reinstallation, suspend air conditioner compressor at a

suitable position under vehicle using a piece of wire.

♦ When doing this, ensure that hoses are not stretched or

kinked.

– Release and disconnect DF wire connector -1-. – Lever off protective cap -2-.

do c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o te itte iva r du p or nl f e ng

Note

ee or ac

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– Remove the two bolts of air

ho ut a conditioner ss

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– Remove nut -1- and remove the battery positive wire, located beneath, from the connector thread of the alternator -C- . – Unscrew nut -3- and remove wiring retainer -2- from the alter‐ nator -C- .

– Unscrew both bolts -1- and nuts -2- of fuel filter -3- and place filter to one side. The fuel hoses can then remain connected.

7. Alternator C

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155

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove the two bolts -arrows- of alternator -C- . – Lower alternator -C- out of vehicle. Installing Install in the reverse order of removal. When doing this, note the following: Caution

♦ When installing used poly V-belts observe the direction of rotation marked on removal! ♦ Before installing poly V-belt, make sure all assemblies ( alternator -C- / air conditioner compressor) are firmly in position. ♦ When fitting belt, ensure that poly V-belt seats correctly in pulleys! – Drive threaded sleeves -A- roughly 4 mm in direction of arrow out of alternator -C- housing.

– Secure wire holder -arrow- on back of alternator -C- in 3 o'clock position.

AG.

Downloaded from www.Manualslib.com manuals search engine

agen lksw Vo by

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Rep. gr.27 - Starter, current supply, CCS

ht rig py Co t.

156

rrectness of i t to the co nform spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e g n

ility ab y li an pt ce

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Tighten threaded connections to specified torques ⇒ page 153 . Caution

Before installing engine cover, check correct position of 4 at‐ tachment elements (ball sockets) and return these to their position. Otherwise, engine cover will be damaged. – Place engine cover on attachment points and press into lock‐ ing points at corners. – Connect battery -A- ⇒ page 4 . Caution

Observe notes for battery pole terminal clamp bolt ⇒ page 1 . – Start engine and check belt is running correctly. – Switch off engine.

rrectness of i t to the co nform spec a t ion h re wit in t his

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o te itte iva r du p or nl f e ng

ility ab y li an pt ce

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ht rig py Co t.

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7. Alternator C

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157

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7.17

Alternator -C- 2.0l TSI engine

7.17.1

Assembly overview

1 - Hexagon head flange bolt ❑ 20 Nm 2 - Cross-head screws ❑ 2 Nm 3 - Washer 4 - Cross-head screw ❑ 4.5 Nm 5 - Hexagon nut ❑ 15 Nm 6 - Hexagon nut 7 - Protective cap for alternator -C8 - Cross-head screw ❑ 2 Nm 9 - Voltage regulator -C1❑ Removing and installing ⇒ page 169

Not illustrated

♦ Nut of B+ wire on rear of alternator: 15 Nm ♦ Nut of wire holder on back of alternator : 3.2 Nm ♦ Poly V-belt pulley without freewheel: 65 Nm ♦ Poly V-belt pulley with freewheel: 80 Nm ♦ Removing and installing ancillary bracket ⇒ Engine; Rep. gr. 13

AG.

Prote cted by

Downloaded from www.Manualslib.com manuals search engine

agen lksw Vo by

cop yri gh t . Co py i

Rep. gr.27 - Starter, current supply, CCS

ht rig py Co t.

158

rrectness of i t to the co nform spec a t i h re o n in wit thi s

11 - Poly V-belt ❑ Removing and installing ⇒ Engine; Rep. gr. 13 ❑ Checking ⇒ page 88 ❑ Poly V-belt routing ⇒ Engine; Rep. gr. 13

do c um en

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e ng

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10 - Alternator -C❑ Removing and installing ⇒ page 159 AG. Volkswagen AG d oes ❑ Checking ⇒ page 89 lkswagen not o V gu by ara ❑ Securing battery posi‐ d e nte s i r tive wire ⇒ page 88 o eo h t u ra a c ❑ Removing and ss installing poly V-belt pulley ⇒ page 163

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

n AG. Volkswagen AG do es n wage ot g olks V y ua db ran e is tee r o h t or u ac a ss

7.17.2

Removing and installing alternator -C-

♦ Torque wrench -V.A.G 1331♦ Locking pin -T10060 A♦ Spring-type clip pliers -VAS 5024 A-

rrectness of i t to the co nform spec at i h re o n wit in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m m ot p r co erm o e t a itte v i r du p or nl f e g n

ility ab y li an pt ce

Special tools and workshop equipment required

ht rig py Co t.

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Prote cted by c o py rig ht . C op yi

Carry out following procedures: Removing – Disconnect battery -A- ⇒ page 4 . Caution

When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 .

7. Alternator C

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159

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Disconnect plug connector -arrow-.

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t a itte iv du pr r o nl f e ng

– Remove charge air hose from vehicle. ht rig py Co t.

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– Unfasten clip -1- and remove hose -2- from activated charcoal filter. Note

For reasons of clarity, the activated charcoal filter bracket is shown removed in the following illustration. The bracket does not need to be removed to release the filter.

160

Rep. gr.27 - Starter, current supply, CCS

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thi sd o cu m en

– Remove bolts -arrows-.

rrectness of i t to the co n f o r m spec atio h re n in wit

– Loosen spring-type clip -arrow- using spring-type clip pliers VAS 5024 A- .

ility ab y li an pt ce

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Slightly lift locking lug on rear of bracket -arrow- using a suit‐ able screwdriver and pull activated charcoal filter -1- upwards out of bracket -2-. – Place activated charcoal filter -1- with connected hose to one side. Caution

Before removing, mark the top side and direction of rotation of the poly V-belt. When installing, ensure correct fitting position and direction of rotation. If the belt is installed in the wrong position or against direction of rotation, the belt will be de‐ stroyed! – Remove poly V-belt ⇒ Engine; Rep. gr. 13 . – Remove both bolts -arrows- and put coolant pipes and hose -1- up to make room for removing alternator -C- . Note

Coolant pipes and hose can remain connected. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 .

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ise tee r o h t or u ac a ss

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

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un le

– Remove bolts of air conditioner compressor -arrows-.

rrectness of i t to the co n f o r m spec atio h re n in wit

– Release and disconnect connector -1-.

ng

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7. Alternator C

thi sd o cu m en

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– Unscrew third bolt -arrow- and remove air conditioner com‐ pressor from bracket.

161

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Note

wire -1- at a suitable position under the vehicle until it is ready to be reinstalled.

♦ Ensure that the hoses -2- are not stretched or kinked when

rrectness of i t to the co nform spec a t i h re o n in wit thi s

doing this.

ility ab y li an pt ce

♦

– Remove the two lower bolts -arrows- of alternator -C- from below.

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– Remove the two bolts -arrows- of alternator -C- .

– Swing alternator -C- slightly to the left to gain access to con‐ nections on generator side. Prote cted by

162

Rep. gr.27 - Starter, current supply, CCS

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AG.

– Release and disconnect DF wire connector -1-.

ht rig py Co t.

– Release and disconnect connector -2-.

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urposes, in part or in wh ole, cial p is n mer m ot p o c r erm te o a itte ir v du p or nl f e ng

♦

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d compressor can remain con‐ The hoses of the air conditioner e nte is r o nected. eo h ut ra a c s s Suspend the air conditioner compressor -3- using a piece of

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

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– Lever off protective cap -1-.

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– Remove nut -2- and remove the battery positive cable -1-, lo‐ cated beneath, from the connector thread of the alternator C- . – Lift alternator -C- out of vehicle. Installing

Install in the reverse order of removal. When doing this, note the following: Caution

♦ When installing used poly V-belts observe the direction of rotation marked on removal! r te o iva r rp fo

ng

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– Tighten threaded connections to specified torques ⇒ page 158 .

ht rig py Co t.

♦ When fitting belt, ensure that poly V-belt seats correctly in pulleys!

thi sd o cu m en

♦ Before installing poly V-belt, make sure all assemblies ( alternator -C- / air conditioner compressor) are firmly in position.

Prote cted by

– Connect battery -A- ⇒ page 4 . Caution

Observe notes for battery pole terminal clamp bolt ⇒ page 1 . – Start engine and check belt is running correctly. – Switch off engine.

7.18

Removing and installing poly-V belt pul‐ ley on alternator -C-

7.18.1

Removing and installing poly V-belt pul‐ ley (without freewheel)

Special tools and workshop equipment required

7. Alternator C

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163

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t itte iva r du p or nl f e ng

– Use socket -VAS 3310- to unscrew poly-V-belt pulley nut from alternator shaft. Installing Carry out installation in the reverse sequence, noting the follow‐ ing: – Tighten threaded connections to specified torques ⇒ page 158 .

Removing and installing poly V-belt pul‐ ley (with freewheel, Bosch)

Special tools and workshop equipment required

164

Rep. gr.27 - Starter, current supply, CCS

Downloaded from www.Manualslib.com manuals search engine

AG.

– Clamp alternator -C- in a vice at holding points of alternator.

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– Remove alternator -C- ⇒ page 88 .

rrectness of i t to the co nform spec a t ion h re wit in t his

Removing

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Carry out following procedures:

7.18.2

ility ab y li an pt ce

♦ Torque wrench -V.A.G 1332-

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ht rig py Co t.

♦ Socket -VAS 3310-

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Multipoint adapter -VAS 3400-

♦ Torque wrench -V.A.G 1332-

Carry out following procedures: Removing

– Remove alternator -C- ⇒ page 88 . – Clamp alternator -C- in a vice at holding points of alternator. – Remove protective cap from poly V-belt pulley with freewheel. Note

The thread on the alternator shaft is left-handed. To loosen the connection, turn clockwise, and to tighten it, turn anti-clockwise. ht rig py Co t.

– Insert multi-point adapter -VAS 3400- with ring spanner in al‐ ternator -C- poly V-belt pulley with freewheel.

rrectness of i t to the co nform spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e g n

ility ab y li an pt ce

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AG.

Prote cted by

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7. Alternator C

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165

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Insert an M10 multi-point bit -1- into alternator shaft. – Loosen threaded connection by turning clockwise. Counter‐ hold with ring spanner when doing this. – Hold poly V-belt pulley with freewheel by hand. Turn drive shaft of alternator -C- until poly V-belt pulley with freewheel AG. Volkswagen AG d can be removed. agen oes ksw n Installing

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm te o a itte ir v du p or nl f e ng

doing this, note the

ot g ua ran tee or ac ility ab y li an pt ce

Install in the reverse order of following:

ol yV db e ris ho ut removal. When a ss

– First screw poly V-belt pulley with freewheel on drive shaft of alternator -C- by hand as far as limit stop.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

The torque wrench -V.A.G 1332- must be modified for assembly of poly V-belt with freewheel as follows:

– Release socket drive -1- and pull off grip -2-. – Turn grip -2- of torque wrench by 180 degrees and reinsert socket drive. – Set turning direction of torque wrench to anti-clockwise on socket drive.

AG.

– Tighten threaded connections to specified torques ⇒ page 158 .

166

Rep. gr.27 - Starter, current supply, CCS

Downloaded from www.Manualslib.com manuals search engine

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– Tighten poly V-belt pulley with freewheel by turning alternator -C- drive shaft anti-clockwise using torque wrench -V.A.G 1332- .

ht rig py Co t.

– Counterhold using multi-point adapter -VAS 3400- and ring spanner.

do c um en

– Insert an M10 multi-point bit -1- into alternator shaft.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7.18.3

Removing and installing poly V-belt pulley (with freewheel, Valeo)

Special tools and workshop equipment required ♦ Multipoint adapter -VAS 3400♦ Torque wrench -V.A.G 1332♦ TORX driver bit -V.A.G 1603/1-

rrectness of i t to the co nform spec a t i h re o n in wit thi s

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o te a itte ir v du p or nl f e ng

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Prote cted by c o py rig ht . C op yi

– Remove alternator -C- ⇒ page 88 .

ht rig py Co t.

Removing

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Carry out following procedures:

– Clamp alternator -C- in a vice at holding points of alternator.

– Remove protective cap from poly V-belt pulley with freewheel. Note

The thread on the alternator shaft is left-handed. To loosen the connection, turn clockwise, and to tighten it, turn anti-clockwise. – Insert multi-point adapter -VAS 3400- with ring spanner in al‐ ternator -C- poly V-belt pulley with freewheel.

7. Alternator C

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167

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Insert TORX driver bit -V.A.G 1603/1- in alternator shaft. – Loosen threaded connection by turning clockwise. Counter‐ hold with ring spanner when doing this. – Hold poly V-belt pulley with freewheel by hand. Turn drive shaft of alternator -C- until poly V-belt pulley with freewheel can be removed. Installing Install in the reverse order of removal. When doing this, note the following: – First screw poly V-belt pulley with freewheel on drive shaft of alternator -C- by hand as far as limit stop. The torque wrench -V.A.G 1332- must be modified for assembly of poly V-belt with freewheel as follows:

– Release socket drive -1- and pull

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– Turn grip -2- of torque wrench by socket drive.

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– Set turning direction of torque wrench to anti-clockwise on socket drive.

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– Insert TORX driver bit -V.A.G 1603/1- in alternator shaft. – Counterhold using multi-point adapter -VAS 3400- and ring spanner. – Tighten poly V-belt pulley with freewheel by turning alternator -C- drive shaft anti-clockwise using torque wrench -V.A.G 1332- .

Removing and installing voltage regula‐ tor -C1- (Bosch)

Special tools and workshop equipment required

168

Rep. gr.27 - Starter, current supply, CCS

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7.19.1

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Voltage regulator -C1- for alternator -C-

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7.19

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– Tighten threaded connections to specified torques ⇒ page 158 .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Torque screwdriver -V.A.G 1624-

Carry out following procedures: Removing – Remove alternator -C- ⇒ page 88 .

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– Undo bolt and nuts -arrows- and detach protective cap from alternator -C- .

– Remove bolts for voltage regulator -C1- -arrows-.

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Installing

Installation is carried out in reverse order of removal.

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– Remove voltage regulator -C1- from alternator -C- .

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– Tighten threaded connections to specified torques ⇒ page 158 .

7.19.2

Removing and installing voltage regula‐ tor -C1- (Valeo)

Special tools and workshop equipment required

7. Alternator C

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169

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Torque wrench -V.A.G 1783/-

Carry out following procedures: Removing – Remove alternator -C- ⇒ page 88 . – Remove clamping rings -arrows- and detach protective cap from alternator -C- .

– Remove voltage regulator -C1- from alternator -C- . Installing

Install in the reverse order of removal. When doing this, note the following:

– Release locking lugs -arrows- and pull protective cap off volt‐ age regulator -C1- .

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– Press carbon brushes into housing of voltage regulator -C1and insert voltage regulator -C1- in alternator -C- . agen lksw Vo by

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– Tighten threaded connections to specified torques ⇒ page 158 .

Rep. gr.27 - Starter, current supply, CCS

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170

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– Remove bolts for voltage regulator -C1- -arrows-.

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7. Alternator C

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171

All the instructions and information for this manual are found in the workshop manual „Electrical System, General Information“. A link to this workshop manual is not possible at present for tech‐ nical reasons. Please select the workshop manual „Electrical System, General Information“ manually in ELSA.

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Rep. gr.27 - Starter, current supply, CCS

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172

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Cruise control system (CCS)

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Gauges, instruments

1

Dash panel insert

General description

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90 –

, Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

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The following components are integrated in the dash panel insert: ♦ Control unit in dash panel insert -J285♦ immobiliser control unit -J362♦ Speedometer -G21♦ Rev. counter -G5♦ Fuel gauge -G1♦ Coolant temperature gauge -G3♦ Multifunction display ht rig py Co t.

♦ Warning lamps ⇒ page 176 Prote cted by c o py rig ht . C op yi

To provide acoustic support to some of the visual displays, the dash panel features a warning buzzer, which is actuated by the control unit in dash panel insert -J285- . agen lksw Vo by

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All warning lamps are fitted with light-emitting diodes (LEDs). No provision is made for dash panel insert repair. If necessary, the dash panel insert is renewed as a unit ⇒ page 173 . The data bus diagnostic interface -J533- is an individual control unit and not part of the dash panel insert ⇒ page 467 , unlike on several other vehicles. Fault detection and fault display The dash panel insert is equipped with self-diagnosis. For fault finding, use vehicle diagnosis, testing and information system -VAS 5051B- in „Guided fault finding“ mode.

1.1

Renewing dash panel insert

The procedure „Renewing dash panel insert“ covers the following additional tasks: ♦ If a new dash panel insert is installed in the vehicle, the control unit in dash panel insert -J285- must be adjusted to the differ‐ ent equipment features and associated country settings. ♦ To adapt integrated immobiliser control unit -J362- to engine control unit -J623- , data from engine control unit -J623- must be stored in replacement dash panel insert. ♦ Furthermore, if a new dash panel insert is installed, all ignition keys must be adapted. Special tools and workshop equipment required

1. Dash panel insert

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173

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Carry out following procedures:

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♦ Vehicle diagnosis, testing and information 5051B-

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– Connect vehicle diagnosis, testing and information system VAS 5051B- .

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♦ Dash panel insert ♦ Functions of dash panel insert ♦ Adapting/renewing dash panel insert

1.2

Removing and installing dash panel in‐ sert (up to MY2009) Note

Before removing the dash panel insert, the work procedure „Re‐ newing dash panel insert“ must always be carried out in order that the data stored in the control unit in dash panel insert -J285- can be interrogated ⇒ page 173 . Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Carry out following procedures: Removing Note

There is no need to remove the steering wheel. – Pull out steering wheel fully and engage steering wheel in low‐ est position.

174

Rep. gr.90 - Gauges, instruments

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♦ 01 - On Board Diagnosis capable systems

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♦ Electrical system

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♦ Body

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– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

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– On vehicle diagnosis, testing and information system -VAS 5051B- select „Guided fault finding“.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove upper part of steering column trim ⇒ General body repairs, interior; Rep. gr. 68 . – Remove bolts -arrows- from dash panel insert. Note

When pulling out dash panel insert, there is no need to separate the connectors. The connections comprise of one part that is fixed to the vehicle and are thus separated automatically when the dash panel insert is pulled out. – Pull dash panel insert out of dash panel. Installing Installation is carried out in reverse order of removal.

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Removing and installing dash panel in‐ sert (from MY2010) Note

Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

Carry out following procedures: Removing

Note

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There is no need to remove the steering wheel.

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Before removing the dash panel insert, the work procedure „Re‐ newing dash panel insert“ must always be performed to read out the data stored in the control unit in dash panel insert -J285⇒ page 173 .

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1.3

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– Pull out steering wheel fully and engage steering wheel in low‐ est position. AG.

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– Remove upper part of steering column trim ⇒ General body repairs, interior; Rep. gr. 68 . – Remove bolts -arrows- from dash panel insert. – Pull dash panel insert backwards straight out of dash panel, taking connected wiring length into consideration.

1. Dash panel insert

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175

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Release retaining clip -1- in direction of -arrow- and disconnect connector -2-. – Remove dash panel insert from vehicle. Installing Install in the reverse order of removal. When doing this, note the following:

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1.4

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– Tighten bolted connections to 1.5 Nm.

Back of dash panel insert (up to MY2009)

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Note

The dash panel insert must not be dismantled. If necessary, the dash panel insert is renewed as a unit. Back 1-

36-pin connector

2-

Warning buzzer

The dash panel insert must not be dismantled. If necessary, the dash panel insert is renewed as a unit. 1-

Warning buzzer

2-

32-pin connector

1.6

Pin assignment of connectors at dash panel insert

For pin assignment of connectors on dash panel insert, refer to ⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐ tions.

1.7

Warning lamp symbols on dash panel insert (up to MY2009) Note

Different versions of dash panel insert are installed depending on the vehicle equipment level. Therefore, the arrangement of the warning lamps may differ.

176

Rep. gr.90 - Gauges, instruments

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Note

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Back

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Back of dash panel insert (from MY2010) ht rig py Co t.

1.5

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 1 - Emissions warning lamp K832 - Fault warning lamp for elec‐ tric accelerator mechanism K132❑ Only vehicles with petrol engine 3 - immobiliser warning lamp K1154 - Warning lamp for alternator -K25 - Bulb failure warning lamp K1706 - Warning lamp for rear fog light -K137 - Coolant shortage warning lamp -K368 - Brake pad warning lamp K329 - Washer fluid level warning n AG. Volkswagen AG do lamp -K37es wage ks Vol

y 10 - Reserveefuel d b warning lamp -K16- thoris au

12 - Seat belt warning system warning lamp -K1913 - ABS warning lamp -K4714 - ESP and TCS warning lamp -K15515 - Brake system warning lamp -K11816 - Cruise control system warning lamp -K3117 - Warning lamp for daytime running lights -K20518 - Tyre pressure monitor warning lamp -K22019 - Water in fuel 20 - Rear seat backrest lock warning lamp -K19321 - Selector lever lock warning lamp -K169❑ only on vehicles with automatic gearbox c o p yri gh t. C op yi

23 - Bonnet open warning lamp -K171AG.

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25 - Oil pressure warning lamp -K3-

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24 - Door open warning lamp -K166-

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22 - Oil level warning lamp -K38-

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26 - Main beam warning lamp -K127 - Steering wheel heating 28 - Warning lamp for trailer operation -K1829 - Glow period warning lamp -K29❑ Only vehicles with diesel engine

1. Dash panel insert

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177

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 30 - Fuel tank flap lock warning lamp -K20131 - Warning lamp for diesel particle filter -K23132 - Electromechanical power steering warning lamp -K161-

1.8

Warning lamp symbols on dash panel insert (from MY2010) Note

Different versions of dash panel insert are installed depending on vehicle equipment. Therefore, the arrangement of the warning lamps may differ. 1 - Glow period warning lamp K29❑ Only vehicles with die‐ sel engine 2 - Fault warning lamp for elec‐ tric accelerator mechanism K132❑ Only vehicles with petrol engine 3 - Warning lamp for diesel par‐ ticle filter -K231-

10 - ABS warning lamp -K4711 - ESP and TCS warning lamp -K15512 - Brake system warning lamp -K11813 - Warning lamp for cruise control system -K3114 - Tyre pressure monitor warning lamp -K220-

15 - Brake pad warning lamp -K32-

16 - „Operate foot brake“ warning lamp ❑ Only vehicles with dual clutch gearbox (DSG)

Rep. gr.90 - Gauges, instruments

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AG.

178

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9 - Seat belt warning system warning lamp -K19-

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8 - Main beam warning lamp K1-

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7 - Washer fluid level warning lamp -K37-

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6 - Warning lamp for rear fog light -K13-

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5 - Bulb failure warning lamp K170-

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4 - Oil pressure warning lamp K3-

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 17 - Reserve fuel warning lamp -K1618 - Door open warning lamp -K16619 - Rear lid open warning lamp -K12720 - Airbag warning lamp -K7521 - Emissions warning lamp -K8322 - Electromechanical power steering warning lamp -K16123 - Coolant shortage warning lamp -K3624 - Warning lamp for alternator -K225 - Not assigned

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1. Dash panel insert

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179

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

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2.1

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⇒ Maintenance ; Booklet 20.1 ; Descriptions of work

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Rep. gr.90 - Gauges, instruments

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180

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

92 –

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Windscreen wiper system

When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 .

General description The wiper motor control unit -J400- and the windscreen wiper motor -V- are combined to form one unit. To remove the wiper blades, the wiper arms should be placed in the „service/winter position“. The „service/winter position“ is acti‐ vated within 10 seconds after ignition is switched off by pressing the windscreen wiper lever in position „tip wipe“ ⇒ Operating manual .

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Fault detection and fault display

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The on-board supply control unit -J519- is equipped with self-di‐ agnosis.

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Windscreen wash/wipe system Volkswa

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Additional information ⇒ Operating instructions

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Deactivating wiper motor control unit J400- APP function AG.

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For fault finding, use vehicle diagnosis, testing and information system -VAS 5051B- in „Guided fault finding“ mode.

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

The windscreen wiper system is equipped with an APP function (alternating park position). With the APP function, the wiper arm is moved up slightly once it has reached the lowest position. This occurs every second time the wiper system is switched off. The wiper motor must be set to the bottom park position for at‐ taching the crank to the motor. This is done by deactivating the APP function (coding wiper motor control unit -J400- ).

1. Windscreen wiper system

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181

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Note ♦ The APP function cannot be activated. ♦ After 100 cycles of wiper movement, the APP function is acti‐

vated automatically. This applies to wiper motors on which the APP function has been deactivated and also to new wiper mo‐ tors.

Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – On vehicle diagnosis, testing and information system -VAS 5051B- select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system ♦ 01 - On Board Diagnosis capable systems ♦ Onboard supply control unit ♦ Functions - onboard supply control unit

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Rep. gr.92 - Windscreen wash/wipe system

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182

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♦ Coding wiper electronics control unit / deactivating APP func‐ tion

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

1.2

Assembly overview - windscreen wiper system

1 - Nut ❑ 20 Nm 2 - Joint-free wipers ❑ Removing and installing ⇒ page 190 ❑ Adjusting park position ⇒ page 188 3 - Wiper arms ❑ Removing and installing ⇒ page 185 4 - Bolt ❑ 8 Nm 5 - Wiper frame with linkage ❑ Removing and installing ⇒ page 186

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7 - Rubber grommet in bulk‐ head ❑ Observe installation notes ⇒ page 188

Not illustrated ♦ Wiper motor -V- bolts to wiper frame with linkage – 8 Nm ♦ Wiper motor crank to wiper motor shaft: 18 Nm

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Caution

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1.3

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wag 6 - Wiper motor -V- with kswiper Vol motor control united-J400by ris ❑ Removing tho from wiper u a frame ss and installing ⇒ page 186 ❑ Coding wiper motor control unit -J400- and deactivating APP func‐ tion ⇒ page 181

When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 . Special tools and workshop equipment required

1. Windscreen wiper system

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183

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Torque wrench -V.A.G 1331-

♦ Release lever -80-200-

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Removing windscreen wiper system

Note

Before the wiper frame with linkage and wiper motor can be re‐ moved, first remove the wiper arms, the plenum chamber cover and the air duct trim.

184

Rep. gr.92 - Windscreen wash/wipe system

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– Disconnect battery -A- ⇒ page 4 .

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– Allow wiper to move to park position and then switch ignition off.

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– Deactivate APP function ⇒ page 181 .

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Procedure

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1.3.1

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♦ Puller -T10369-

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

1.3.2

Removing wiper arms

– Lever off the cover caps -arrows- using a suitable screwdriver. – Remove securing nut -arrows-.

Caution

The wiper shaft may be damaged. Always use the thrust piece -3- to loosen the wiper arm. – Turn thrust bolt -1- of puller clockwise until thrust piece -3comes into contact with wiper shaft. Turn thrust bolt -1- of puller clockwise using an Allen key until wiper arm -4- comes off shaft. – Remove puller and wiper arm.

1.3.3

Removing plenum chamber cover

Removing and installing plenum chamber cover ⇒ General body repairs, exterior; Rep. gr. 64 .

Removing air ducting trim

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– Take air duct trim -3- upwards out of vehicle.

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– Remove bolt -1- and nut -2- from air duct trim -3-.

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1.3.4

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– Slide legs of puller -T10369/1- -2- under wiper arm -4- as shown in the illustration.

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1. Windscreen wiper system

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185

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

1.3.5

Removing wiper frame with linkage and wiper motor -V-

Procedure – Disconnect connector -1-. – Remove bolts -arrows- and pull wiper frame -2- upwards off vehicle.

1.3.6

Removing wiper motor -V- from wiper frame

Procedure

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– Remove nut -1-.

– Pull motor crank -2- off wiper motor shaft. – Unscrew bolts -arrows- and remove wiper motor -V- together with wiper motor control unit -J400- from wiper frame.

AG.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

1.3.7

Installing wiper motor -V- in wiper frame

Procedure – Insert wiper motor -V- with wiper motor control unit -J400- in wiper frame and secure it with bolts -arrows-. – Tighten threaded connections to specified torques ⇒ page 183 . – Place motor crank -1- on shaft of wiper motor -V- .

Distance -a- to limit stop -2- should be 3 ± 1 mm. – Connect motor crank to shaft of wiper motor -V- using nut -3-. – Tighten threaded connections to specified torques ⇒ page 183 .

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– Press ball head -arrow- of linkage -1- onto motor crank.

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1. Windscreen wiper system

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1.3.8

Installing windscreen wiper system

Procedure – Install wiper frame in reverse order of removal. Note when in‐ stalling that securing pin -2- of wiper frame must be inserted in grommet -1- in plenum chamber bulkhead. – Tighten threaded connections to specified torques ⇒ page 183 . – Fit connector to wiper motor -V- connection and lock in posi‐ tion. – Install air cowling and plenum chamber cover in reverse order of removal. – Install the plenum chamber cover ⇒ General body repairs, exterior; Rep. gr. 64 . – Connect battery -A- ⇒ page 4 . – Install wiper arms ⇒ page 188 .

1.4

Removing and installing wiper arms

Removing

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– Removing wiper arms ⇒ page 185

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Nuts of wiper arms are not tightened to specified torque until after wiper blade park position has been adjusted. – Deactivate APP function ⇒ page 181 .

– To move wiper motor -V- to park position, switch wipers on and off with ignition on. – Insert wiper arms in approximate park position onto wiper arm shafts and tighten nuts -arrows- by hand. – Adjust windscreen wiper blade park position ⇒ page 188 .

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188

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Special tools and workshop equipment required

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Adjusting wiper blade park position

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➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

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On RHD vehicles, the wiper blades are a mirror image of those on LHD vehicles. Procedure – Deactivate APP function ⇒ page 181 . ht rig py Co t.

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Driver side

Distance -A- between end of wiper blade and upper edge of ple‐ num chamber cover must be 10 mm. – If necessary, adjust wiper blade park position by moving wiper arm. Removing wiper arms ⇒ page 185 – Tighten threaded connection to specified torque ⇒ page 183 .

Front passenger side Distance -B- between end of wiper blade and upper edge of ple‐ num chamber cover must be 10 mm. – If necessary, adjust wiper blade park position by moving wiper arm. Removing wiper arms ⇒ page 185 – Tighten threaded connection to specified torque ⇒ page 183 .

1. Windscreen wiper system

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

1.6

Removing and installing joint-free wiper blades Note

♦ Driver and front passenger wiper blades must not be inter‐

changed during installation.

♦ Joint-free wiper blades are very flexible. To lift the wiper blades

off the windscreen, touch them only in the area in which the wiper blades are attached to the wipers.

♦ To remove the wiper blades, the wiper arms should be placed

in the „service/winter position“. The „service/winter position“ is activated within 10 seconds after ignition is switched off by pressing the windscreen wiper lever in position „tip wipe“.

Removing – Place wiper arms in „service/winter position“ by pressing wind‐ screen wiper lever to „flick wipe“ position 10 seconds after ignition has been switched off. – Lift up wiper arm. – Turn wiper blade -1- on wiper arm onto stop -arrow A-. – Pull wiper blade -1- off axis of wiper arm -arrow B-. Installing – Slide wiper blade onto axis of wiper arm. AG. Volkswagen AG do n es n wage ot g olks onto stop. – Turn wiper blade on axis of wiper arm V u by

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ris – Carefully fold wiper arm back tho down onto windscreen.

If an intact rain and light sensor -G397- has to be removed from its retaining plate on the windscreen (replacement of windscreen), it can be subsequently reinstalled. If the front windscreen is cracked in the area of the rain and light sensor -G397- before removal, the rain and light sensor -G397- cannot be used again. On removal, store the rain and light sensor -G397- in a dust-free location until reinstallation and ensure the silicone contact pad is not soiled. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

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– Remove interior mirror ⇒ General body repairs, interior; Rep. gr. 68 . Prote cted

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AG.

190

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Removing and installing rain and light sensor -G397-

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1.7

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Disconnect connector -A- from rain and light sensor -G397-1-. Note

There is not a recess 3 on all rain and light sensors -G397- . If there is no opening, lever out at another suitable place.

– Using a suitable plain slot screwdriver, lever rain and light sensor -G397- -1- on recess -3- out of retaining plate -2-. AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h t u ra a entire rain and light sensor outssthe c

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On removal, take care to prise -G397- and not just the upper shell of the rain and light sensor G397- .

Carry out installation in the reverse sequence, noting the follow‐ ing: – Thoroughly clean the windscreen inside the retaining plate with isopropanol (isopropyl alcohol) ⇒ General body repairs, interior; Rep. gr. 68 . – Remove protective cap on new rain and light detector sensor -G397- . Note

♦ The surface (contact pad) of the rain and light sensor -G397♦ If the surface (coupling pad) of the rain and light sensor -G397ng

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1. Windscreen wiper system

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191

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Seat the rain and light sensor -G397- -1- in the retaining plate -2- on the windscreen and press it on until secure. Note

About 10 minutes after installation, there must not be any air bub‐ bles between the front windscreen and the contact pad of the rain and light sensor -G397- .

– Reconnect the connector -A- and secure the rain and light sensor -G397- -1- by installing the cable cover. – Install interior mirror ⇒ General body repairs, interior; Rep. gr. 68 . AG. Volkswagen AG d oes not gu ara nte eo ra c

agen – Code the rain and light sensor -G397lksw ⇒ page 192 .

1.8

Coding rain and light sensor -G397-

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

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– Connect vehicle diagnosis, testing and information system VAS 5051B- . AG.

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– In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system

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Procedure

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ 01 - On Board Diagnosis capable systems ♦ Onboard supply control unit ♦ Functions - onboard supply control unit

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♦ Coding rain/light sensor

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1. Windscreen wiper system

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

2

Windscreen washer system Note

Additional information: ⇒ Operating instructions

2.1

Assembly overview - windscreen washer system

1 - Y-piece ❑ Distribution of washer fluid line to windscreen washer system spray jets 2 - Right washer jet for wind‐ screen washer system ❑ Removing and installing ⇒ page 199 ❑ Adjusting ⇒ page 199 3 - Left washer jet windscreen washer system ❑ Removing and installingwagen AG. Volkswagen AG doe s no ks ⇒ page 199 t gu Vol by ara d nte ir se 199 ❑ Adjusting ⇒ page o

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4 - Angled piecess a ❑ Connection to left wind‐ screen washer system spray jet ❑ Overview of hose cou‐ plings for washer fluid lines ⇒ page 212 5 - Hose ❑ Hose repair ⇒ page 213 6 - Angled piece ❑ Connection to right windscreen washer sys‐ tem spray jet ❑ Overview of hose cou‐ plings for washer fluid lines ⇒ page 213

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8 - Windscreen and rear window washer pump -V59❑ Removing and installing ⇒ page 197

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9 - Windscreen washer and headlight washer system reservoir ❑ Removing and installing ⇒ page 196 ❑ Removing and installing ⇒ page 198

194

Rep. gr.92 - Windscreen wash/wipe system

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AG.

- Windscreen washer fluid level sender -G33-

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7 - Reservoir filler neck for windscreen and headlight washer system ❑ Removing and installing ⇒ page 195

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Not illustrated ♦ Reservoir for windscreen and headlight washer systems to body - 8 Nm

2.2

Removing and installing washer fluid reservoir

Washer fluid reservoir has 3 parts. The individual parts are com‐ bined together as a unit. In order to ensure the parts are placed together correctly, check when assembling that the guides of the individual parts engage in each other. 1 - Removing and installing filler neck for washer fluid reservoir ⇒ page 195 . 2 - Connecting pipe between filler neck and reservoir. Connecting pipe is removed together with washer fluid reservoir ⇒ page 196 . Volkswage n AG wage

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Removing

Removing and installing washer fluid reservoir filler neck

– Pull connecting pipe -1- off filler neck -3- on washer fluid res‐ ervoir. – Remove bolt -2-.

– Unclip hose retainer from filler neck -3- and remove from ve‐ hicle. Install in the reverse order of removal. When doing this, note the following: agen lksw Vo by

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The protrusion on the underside of the filler neck should be in‐ serted in the hole -arrow-.

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2.2.1

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2. Windscreen washer system

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195

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Connecting pipe -1- and filler neck -2- should be pressed together so that the guides -arrows- engage in each other.

2.2.2

Removing and installing washer fluid reservoir Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Remove filler neck for washer fluid reservoir ⇒ page 195 . . Volkswag AG agen

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– To release, turn securing clips at hose connections -3- and -5- and pull these off windscreen and rear window washer pump -V59- -4-. – Drain any escaping fluid in a suitable container. – Disconnect connector -6- for windscreen washer fluid level sender -G33- -7-. – Pull windscreen and rear window washer pump -V59- -4- up‐ wards out of reservoir and disconnect connector -2-. – Pull headlight washer pump -V11- -9- upwards out of reservoir and disconnect connector -10-.

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Rep. gr.92 - Windscreen wash/wipe system

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196

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The connections to the windscreen and rear window washer pump -V59- and hose lines are colour-coded in order to prevent the washer fluid lines being incorrectly connected to the wind‐ screen and rear window washer pump -V59- . The hose fittings must be connected to the correct colour-coded pump connections during installation.

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– Unscrew bolts -arrows- from reservoir and remove reservoir from vehicle.

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Installing

Install in the reverse order of removal. When doing this, note the following: – Tighten all threaded connections to specified torques ⇒ page 194 . – On completion of installation work, bleed headlight washer system ⇒ page 210 .

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AG.

Caution

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Removing and installing windscreen and rear window washer pump -V59-

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2.3

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Remove front bumper cover ⇒ General body repairs, exterior; Rep. gr. 63 . Note

The connections to the windscreen and rear window washer pump -V59- and hose lines are colour-coded in order to prevent the washer fluid lines being incorrectly connected to the wind‐ screen and rear window washer pump -V59- . The hose fittings must be connected to the correct colour-coded pump connections during installation.

2. Windscreen washer system

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197

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ swagen AG Electrical system -eEdition n AG. Volk07.2010 does not gu ar-3hose connections an and tee and rear window washer or ac

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– Drain any escaping fluid in a suitable container.

– Pull windscreen and rear window washer pump -V59- -4- up‐ wards out of reservoir. Installing

Install in the reverse order of removal. When doing this, note the following: – Tighten all threaded connections to specified torques ⇒ page 194 . – On completion of installation work, bleed headlight washer system ⇒ page 210 .

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Caution

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♦ Switch off ignition and all electrical consumers. AG.

♦ Remove the ignition key.

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Removing and installing windscreen washer fluid level sender -G33ht rig py Co t.

2.4

Removing – Remove front bumper cover ⇒ General body repairs, exterior; Rep. gr. 63 . – Disconnect connector -1- on windscreen washer fluid level sender -G33- -2-. – Pull windscreen washer fluid level sender -G33- -2- out of its rubber seal. – Drain any escaping fluid in a suitable container. Installing Install in the reverse order of removal. When doing this, note the following: – On completion of installation work, bleed headlight washer system ⇒ page 210 .

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– Disconnect connector -2-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

2.5

Removing and installing windscreen washer system spray jets

Removing – Push spray jet upwards -arrow A- and pull it out of bonnet from rear -arrow B-.

– Pull hose -1- off spray jet and disconnect connector -2-. Installing – Fit connector -2- and hose -1- on spray jet. – Push spray jet in installation hole until it is heard to lock in place. – Adjust spray jets ⇒ page 199 .

2.6

Adjusting windscreen washer system spray jets

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⇒ Maintenance ; Booklet 20.1 ; Descriptions of work

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direction. Purging with compressed air against the spraying di‐ rection is then permitted. Do not use objects to clean the spray jets!

2. Windscreen washer system

199

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

3

Rear window wiper system Note

Additional information: ⇒ Operating instructions

3.1

Assembly overview - rear window wiper system

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4 - Seal

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5 - Spray jet ❑ Renewing ⇒ page 206 ❑ Adjusting ⇒ page 206 6 - Seal

7 - Rear window wiper motor V12❑ Removing and installing ⇒ page 201 8 - Nut ❑ 8 Nm

9 - Rubber ring 10 - Spacer

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Removing rear window wiper

3.2.1

Removing and installing wiper arm

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3.2

Removing – To place wiper motor in its park position, switch rear window wiper on and off with ignition on. – Lift up and unclip cap -1- of rear window wiper.

200

Rep. gr.92 - Windscreen wash/wipe system

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11 - Wiper blade ❑ Removing and installing aerodynamic wipers ⇒ page 203 .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Loosen hexagon nut -arrow- without removing it completely. Note

Aerodynamic wipers are very flexible. To lift the wiper blade off the rear window, grasp it only in the area in which the wiper blade is attached to the wiper. – Lift up wiper arm and free off from taper by rocking from side to side. – Unscrew nut -arrow- and remove from wiper arm. Installing – With ignition switched on, switch rear window wiper on and off to run rear window wiper motor -V12- to its rest position. olkswagen AG en AG. V does not gu ara nte eo ra c

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Removing and installing rear window wiper motor -V12Caution

When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 .

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– Removing lower trim of rear lid ⇒ General body repairs, inte‐ rior; Rep. gr. 70 .

AG.

– Disconnect battery -A- ⇒ page 4 .

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Remove wiper arm before removing rear window wiper motor V12- ⇒ page 200 .

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3.2.2

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3. Rear window wiper system

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201

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Release and disconnect connector -3-. – Release hose connection -2- by pulling securing ring upwards and pull hose off connection on rear window wiper motor -V12-1-. – Unscrew hexagon nuts -arrows-. – Carefully pull rear Installing pe rm itte d

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– Before installing rear window wiper motor -V12- , moisten in‐ ner side of seal in rear window with a rubber and plastic compatible lubricant (polyethylene glycol).

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– Check seal is seated correctly in opening of rear window. Mark -1- on seal must align with mark -2- on rear window. – Connect battery -A- ⇒ page 4 .

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Adjusting rear window wiper park posi‐ tion

202

Rep. gr.92 - Windscreen wash/wipe system

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♦ Torque wrench -V.A.G 1331-

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Special tools and workshop equipment required

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3.3

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– Tighten threaded connections to specified torques ⇒ page 200 .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Procedure Distance -a- between wiper rubber and lower edge of window must be 23 mm. – If necessary, adjust rear window wiper park position by moving wiper arm on shaft. Removing wiper arm ⇒ page 200 – Tighten threaded connections to specified torques ⇒ page 200 .

3.4

Removing and installing joint-free wiper blades Note

Joint-free wiper blades are very flexible. To lift the wiper blade off the rear window, grasp it only in the area in which the wiper blade is attached to the wiper. Removing – Pull wiper

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– Pull wiper

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– Remove wiper blade fitting -1- from wiper arm shaft -2-.

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3. Rear window wiper system

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203

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Fit the wiper blade fitting -1- onto the shaft -2- of the wiper arm -3-. – Push on the wiper blade fitting until it engages in the wiper arm. – Carefully fold wiper arm back down onto rear window.

AG.

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Rear window washer system es, in part or in w l purpos hole ercia , is n m m ot p r co erm o e t a itte v i r du p or nl f e ng

⇒ Operating instructions

Assembly overview - rear window washer system

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2 - Connection piece ❑ Point of separation, pas‐ senger compartment wiring harness to rear lid wiring harness ❑ Overview of hose cou‐ plings for washer fluid lines ⇒ page 213

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1 - Connection piece ❑ Connection to rear win‐ dow washer system spray jet ❑ Overview of hose cou‐ plings for washer fluid lines ⇒ page 213

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Additional information:

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4.1

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3 - Rear window washer sys‐ tem spray jet ❑ Removing and installing ⇒ page 206 ❑ Adjusting ⇒ page 206 4 - Filler pipe of reservoir for windscreen washer and head‐ light washer systems ❑ Removing and installing ⇒ page 195 5 - Windscreen washer and headlight washer system res‐ ervoir ❑ Removing and installing ⇒ page 195 6 - Windscreen and rear win‐ dow washer pump -V59❑ Removing and installing ⇒ page 197 7 - Windscreen washer fluid level sender -G33❑ Removing and installing ⇒ page 198 8 - Hose ❑ Hose repair ⇒ page 213

4. Rear window washer system

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

4.2

Removing and installing washer jet Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

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Removing

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– Allow wiper to come to park position.

– Lift up cover cap of rear window wiper arm.

Installing

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– Pull spray jet out of wiper arm shaft using suitable pliers -arrow-. – Push spray jet onto stop in wiper arm shaft with spray jet opening facing upwards. – Adjust spray jet ⇒ page 206 .

Adjusting spray jet

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AG.

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⇒ Maintenance ; Booklet 20.1 ; Descriptions of work

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If impurities in the spray jet cause an uneven spray field, remove the spray jet and flush through with water against the spraying direction. Purging with compressed air against the spraying di‐ rection is then permitted. Do not use objects to clean the spray jets!

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4.3

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

5

Headlight washer system

Every fifth time the windscreen washer system is activated the headlights are also washed if the windscreen wiper lever on the steering wheel is pulled for at least 1.5 seconds and dipped beam or main beam are switched on. The spraying time of the headlight washer system can be adjus‐ ted from between 0 and 12.75 seconds ⇒ page 455 . Following installation work or on initial start-up of the headlight washer system, the system must be bled to ensure proper oper‐ ation of the pop-up cylinders and spray jets ⇒ page 210 . Fault detection and fault display The on-board supply control unit -J519- is equipped with self-di‐ agnosis. For fault finding, use vehicle diagnosis, testing and information system -VAS 5051B- in „Guided fault finding“ mode. Additional information ⇒ Current flow diagrams, Electrical fault finding and Fitting locations ⇒ Operating manual .

5.1

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2 - Spray jet assembly with left spray jets ❑ Removing and installing spray jet assembly ⇒ page 209 ❑ Adjusting spray jets ⇒ page 210 ❑ Removing and installing spray jet pop-up cylin‐ der ⇒ page 209 ht rig py Co t.

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3 - Angled connection piece ❑ Connection to left spray jet pop-up cylinder ❑ Overview of hose cou‐ plings for washer fluid lines ⇒ page 213

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1 - Spray jet assembly right spray jets ❑ Removing and installing spray jet assembly ⇒ page 209 ❑ Adjusting spray jets ⇒ page 210 ❑ Removing and installing spray jet pop-up cylin‐ der ⇒ page 209

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4 - Hose 5 - Angled connection piece ❑ Connection to right spray jet pop-up cylin‐ der ❑ Distribution of washer fluid line to washer jets ❑ Overview of hose cou‐ plings for washer fluid lines ⇒ page 213 5. Headlight washer system

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207

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 6 - T-piece ❑ Distribution of washer fluid line to washer jets 7 - Angled piece 8 - Headlight washer system pump -V11olkswagen AG en AG. V does ❑ Removing and installing ⇒ page 208 olkswag not gu yV b ara d e nte 9 - Windscreen washer and headlight washer system reservoir is r o eo h t u ra ❑ Removing and installing ⇒ page 195 c sa un le

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10 - Filler pipe of reservoir for windscreen washer and headlight washer systems ❑ Removing and installing ⇒ page 195

Pop-up spray jet cylinder to front bumper cover - 4.5 Nm

5.2

Removing and installing headlight washer system pump -V11-

The headlight washer system pump -V11- is mounted on the washer fluid reservoir in the right-hand wheel housing. Caution

Prote cted by

– Pull headlight washer pump -V11- -9- upwards out of reservoir.

AG.

– Disconnect connector -10-. – To remove the connecting pipe -8-, pull out securing clip and pull connecting pipe -8- off headlight washer system pump V11- . Installing Install in the reverse order of removal. When doing this, note the following: – Tighten all threaded connections to specified torques ⇒ page 207 . – On completion of installation work, bleed headlight washer system ⇒ page 210 .

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– Remove front bumper cover ⇒ General body repairs, exterior; Rep. gr. 63 .

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♦ Remove the ignition key.

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♦ Switch off ignition and all electrical consumers.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

5.3

Removing and installing spray jet popup cylinders Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

– Unclip cover cap -1- from mounting points -arrows- on spray jet assembly. – Remove front bumper cover ⇒ General body repairs, exterior; Rep. gr. 63 .

– Pull retainer -4- off hose connection. – Pull hose connection off pop-up spray jet cylinder -2-. – Remove bolt -1-.

– Unclip pop-up spray jet cylinder -2- out of bracket -3Install in the reverse order of removal. When doing this, note the following: Prote cted b y c op yri gh t . Co py i

– The hose leading to the pop-up spray jet cylinder must be clip‐ ped into the hose retainer.

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– Tighten all threaded connections to specified torques ⇒ page 207 .

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Installing

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– On completion of installation work, bleed headlight washer system ⇒ page 210 .

5.4

Removing and installing spray jet as‐ sembly Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

5. Headlight washer system

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209

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Removing – Pull spray jet with cover cap -1- to stop out of bumper cover. – Unclip cover cap -1- from mounting points -arrows- on spray jet assembly.

– Lever locking lug -arrow- up slightly and pull out spray jet as‐ sembly. Installing Note

The degree to which the cover cap of the spray jet is pulled down onto the bumper cover can be adjusted using the clips on the spray jet assembly. If the spray jet assembly is not pulled in far enough, the cover cap will not seat correctly. If the spray jet as‐ sembly is pulled in too far, the cover cap and the bumper cover could be pushed out of shape. G. Volkswage –

– Check the cover cap is seated correctly on the bumper cover.

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– If necessary, adjust seat of cover cap by pushing spray jet assembly in higher or lower position on pop-up cylinder.

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– On completion of installation work, bleed headlight washer system ⇒ page 210 . – Check headlight washer system spray jets and adjust if nec‐ essary ⇒ page 210 .

5.5

Adjusting headlight washer system spray jets

⇒ Maintenance ; Booklet 20.1 ; Descriptions of work

5.6

Bleeding headlight washer system

To guarantee sound functioning of pop-up cylinders and spray jets, the headlight washer system must be bled following assem‐ bly work or when operated for the first time.

– Fill washer fluid reservoir. – Start the engine.

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AG.

Procedure

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Apply handbrake and make sure that gearshift is set to „P“.

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WARNING

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–

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Switch headlights to „ON“. – Operate headlight washer system several times (3-5 times, 3 seconds each time). – Repeat this bleeding procedure until the pop-up cylinders and spray jets are functioning soundly.

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5. Headlight washer system

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 AG. Volkswagen

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212

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All the instructions and information for this manual are found in the workshop manual „Electrical System, General Information“. A link to this workshop manual is not possible at present for tech‐ nical reasons. Please select the workshop manual „Electrical System, General Information“ manually in ELSA.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7

Hose repair

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7. Hose repair

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213

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

94 –

AG. Volkswagen AG d agen Lights, bulbs, switches - exterior oes ksw not l o V gu ara nte eo ra c

Headlights with halogen bulbs (up to MY2009)

Note

♦ Before working on headlights, always switch off the headlights

and remove the ignition key.

♦ When dealing with complaints, it is absolutely necessary to

understand the functions and the operation of the lighting sys‐ tem ⇒ Operating instructions .

The vehicle is fitted with headlights from two different manufac‐ turers: ♦ AL (Automotive Lighting) ♦ Hella

Removal and installation of the headlights are the same except for removal and installation of the control motors. Fault detection and fault display The on-board supply control unit -J519- is equipped with self-di‐ agnosis.

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For fault finding, use vehicle diagnosis, testing and information system -VAS 5051B- in „Guided fault finding“ mode. AG.

Assembly overview

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1.1 Note

The exploded view does not show the control motors, as removal and installation differ from each other.

214

Rep. gr.94 - Lights, bulbs, switches - exterior

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 1 - Bolt ❑ 4 Nm 2 - Adjustment bushes olkswagen AG en AG. V does ❑ Adjusting headlight agin‐ ksw not l o V gu stallation position y ara db nte ⇒ page r217 ise ho ut

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a 3 - Left headlight main beam ss bulb -M30- / right headlight main beam bulb -M32❑ Bulb: H7U 12 V/55 W ❑ Renewing ⇒ page 220

4 - Left side light bulb -M1- / right side light bulb -M3❑ Bulb: 12 V/5 W ❑ Renewing ⇒ page 222 5 - Cover cap 6 - Front left turn signal bulb M5- / front right turn signal bulb -M7❑ Bulb: 12 V/21 W ❑ Renewing ⇒ page 223 7 - Bulb holder with grip

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10 - Bulb holder with grip

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11 - Left headlight dipped beam bulb -M29- / right head‐ light dipped beam bulb -M31❑ Bulb: H7 12 V/55 W ❑ Renewing ⇒ page 218

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9 - Cover cap

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8 - Body aperture

12 - Headlight ❑ Removing and installing ⇒ page 215 ❑ Adjusting headlight installation position ⇒ page 217 ❑ Repairing headlight securing tabs ⇒ page 231

1.2

Removing and installing headlight Note

♦ You do not have to disconnect the earth wire of the battery -

A- .

♦ The illustrations show removal and installation for the left

headlight.

♦ If a headlight is removed, it should always be adjusted follow‐

ing installation ⇒ Maintenance ; Booklet 20.1 ; Description of work .

♦ If a headlight with gas discharge bulbs is removed, the basic

setting of the headlight should always be checked when rein‐ stalling ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

1. Headlights with halogen bulbs (up to MY2009)

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215

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Unclip the connector -arrow- and detach it. – Remove front bumper ⇒ General body repairs, exterior; Rep. gr. 63 .

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AG.

Rep. gr.94 - Lights, bulbs, switches - exterior

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216

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– Remove bolt -arrow- from bottom left of headlight.

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– Remove bolt -arrow- from top of headlight.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove bolt -arrow- from bottom right of headlight. Installing . Volkswage

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r – Tighten all threaded connections to specified torques ho ut a ⇒ page 214 . s s

– Check headlight installation position is central, i.e. shut lines/ gaps are equal around headlight.

– Check headlight functions. – Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

1.3

Adjusting headlight installation position

Note

♦ To adjust the installation position of the headlight, the front

bumper does not have to be removed.

♦ The illustrations show the left headlight. ht rig py Co t.

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Caution

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If it transpires during checking of the installation position that the shut lines/gaps between headlight and body are uneven, the in‐ stallation position must be adjusted.

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If the shut lines/gaps around the headlight are uneven, the instal‐ lation position must be adjusted ⇒ page 217 .

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Procedure – Remove the radiator grille ⇒ General body repairs, exterior; Rep. gr. 66 . – Loosen screw -arrow- at top of headlight.

1. Headlights with halogen bulbs (up to MY2009)

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217

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r o eo h t u ra a c ss

– Loosen screw -arrow- at bottom left of headlight.

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– Loosen screw -arrow- at bottom right of headlight.

Prote cted by

– Check headlight functions. – Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

1.4

Renewing bulbs

1.4.1

Renewing headlight dipped beam bulb

Note

The diagrams show renewal of the left headlight dipped beam bulb -M29- for the left headlight. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

218

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AG.

– Install the radiator grille ⇒ General body repairs, exterior; Rep. gr. 66 .

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– Check and readjust headlight to ensure gaps are even all round.

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– Tighten all threaded connections to specified torques ⇒ page 214 .

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– Adjust flush fit with body by screwing in or screwing out ad‐ justment bushing -arrow- at bottom left and bottom right of headlight.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Removing – Turn cover cap -1- in -direction of arrow- and remove.

– Turn bulb holder with dipped beam headlight bulb -M29- -1- in -direction of arrow- and remove from headlight.

– Pull left headlight dipped beam bulb -M29- -2- in -direction of arrow- out of bulb holder -1-. Installing

Caution

♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over. ♦ When installing cover cap, ensure that it seats properly. The ingress of water will lead to permanent damage to the headlight. – Insert left headlight dipped beam bulb -M29- -1- in bulb holder so that lug at left headlight dipped beam bulb -M29- is posi‐ tioned in recess -arrow- of bulb holder -2-.

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1. Headlights with halogen bulbs (up to MY2009)

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219

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Place bulb holder with left headlight dipped beam bulb -M29-1- in headlight and turn bulb holder with left headlight dipped beam bulb -M29- in -direction of arrow-.

– Insert cover cap -1- in recess on headlight and turn cover cap in direction of -arrow- to secure. – Check headlight functions. – Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

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Note

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1.4.2

The diagrams show renewal of the left headlight main beam bulb -M30- for the left headlight. Caution

♦ Switch off ignition and all electrical consumers.

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220

AG.

– Remove cover cap -1-.

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Removing

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♦ Remove the ignition key.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Disconnect connector -2-.

– Push retaining clip -2- in -direction of arrow- under locking lugs -1- and lift up retaining clip -2-.

Caution

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–

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r o eo h Take left headlight main beam bulb -M30- -1- out of aheadlight. ut ra c ss

♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over. ♦ When installing cover cap, ensure that it seats properly. The ingress of water will lead to permanent damage to the headlight. Carry out installation in the reverse sequence, noting the follow‐ ing: – Place left headlight main beam bulb -M30- -1- in recesses -arrows- of headlight.

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– Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

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1. Headlights with halogen bulbs (up to MY2009)

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– Check headlight functions.

221

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1.4.3

Renewing side light bulb

Note

The diagrams show renewal of the left side light bulb -M1- for the left headlight. AG. Volkswagen AG d agen oes ksw not l o V gu by ara d nte ir se o Switch off ignition andthall electrical consumers. eo u ra c sa s Remove the ignition key.

Caution

Removing

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– Remove cover cap -1-.

– As far as the wiring lengths allow, pull bulb holder -1- with left side light bulb -M1- out of reflector.

AG.

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♦

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull left side light bulb -M1- -2- in -direction of arrow- out of bulb holder -1-. Installing Caution

♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over. ♦ When installing cover cap, ensure that it seats properly. lkswag The ingress of water willolead toenpermanent damage to the AG do en AG. V es n headlight.Volkswag ot

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– Check headlight functions.

1.4.4

Renewing front turn signal bulb

Note

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– Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

The illustrations show the renewal of the front left turn signal bulb -M5- for the left headlight. Caution

♦ Switch off ignition and all electrical consumers.

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1. Headlights with halogen bulbs (up to MY2009)

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223

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Removing – Turn bulb holder with front left turn signal bulb -M5- -1- in di‐ rection of arrow and remove from headlight. – Push front left turn signal bulb -M5- into bulb holder, turn front left turn signal bulb -M5- anti-clockwise and pull front left turn signal bulb -M5- out of bulb holder. Installing Caution

♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over. ♦ When installing cover cap, ensure that it seats properly. The ingress of water will lead to permanent damage to the headlight. Carry out installation in the ing:

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– Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

1.5

Removing and installing headlight range control motor

⇒ page 224 ⇒ page 227 ⇒ page 229

1.5.1

Removing and installing headlight range control motor (Automotive Lighting)

Note

♦ If control motors are removed and reinstalled or renewed, the

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Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Remove headlight ⇒ page 215 .

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AG.

trol motor -V49- on the right headlight. If the left headlight range control motor -V48- is removed and installed, two as‐ sembly openings with predetermined breaking points must be opened to gain access to the bolts (these are not shown on the following illustrations).

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♦ The illustrations show the renewal of the headlight range con‐

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headlight adjustment must be checked and the headlights ad‐ justed ⇒ Maintenance ; Booklet 20.1 ; Description of work .

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– Check headlight functions.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Turn cap -1- in -direction of arrow- and remove. Note

To gain access to the second bolt on the right headlight range control motor -V49- , break open the assembly opening at the predetermined breaking point -arrow- on the back of the headlight housing. This opening must be sealed on completion of repairs with separately available sealing plug.

– Fit a socket on the plastic hexagon on the back of the headlight housing. – Press and turn the plastic hexagon out of the headlight hous‐ ing to break open the assembly opening. Note

The broken open sealing piece must not remain in the headlight. Remove it from the headlight housing.

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– Lift dipped beam reflector -2- in headlight slightly and turn the right headlight range control motor -V49- -1- in -direction of arrow- on to stop.

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1. Headlights with halogen bulbs (up to MY2009)

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225

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Lift dipped beam reflector in headlight slightly and turn the ball head of the right headlight range control motor -V49- -1- so that it can be slid out of the ball head mounting -2- in -direction of arrow- to the rear. – Take the right headlight range control motor -V49- out of the headlight as far as the connected wiring allows.

– Disconnect connector -1- and remove right headlight range control motor -V49- -2-. Installing Carry out installation in the reverse sequence, noting the follow‐ ing:

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– Insert right headlight range control motor -V49- -1- in headlight in position as shown in illustration.

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226

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– Lift dipped beam reflector in headlight slightly and turn the ball head of the right headlight range control motor -V49- -2- so that it can be pushed into the ball head mounting -3- in -direction of arrow-.

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– Reconnect connector -1- on right headlight range control mo‐ tor -V49- -2-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Lift dipped beam reflector in headlight slightly and turn the right headlight range control motor -V49- -1- in -direction of arrowon to stop.

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When installing cover cap, ensure cap is seated correctly. The ingress of water will lead to permanent damage to the head‐ light. – Seal the broken-open assembly openings -1- using a sepa‐ rately ordered sealing plug ⇒ ETKA (electronic parts cata‐ logue) . – Check headlight functions.

– Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

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Removing and installing headlight range control motor (Hella)

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1.5.2

♦ If control motors are removed and reinstalled or renewed, the

headlight adjustment must be checked and the headlights ad‐ justed ⇒ Maintenance ; Booklet 20.1 ; Description of work .

♦ The illustrations show the renewal of the headlight range con‐

trol motor -V49- on the right headlight. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Remove headlight ⇒ page 215 .

1. Headlights with halogen bulbs (up to MY2009)

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227

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Turn cover cap -1- in -direction of arrow- and remove.

– Pull off connector -2-.

– Move right headlight range control motor -V49- -1- so that ball head -3- of right headlight range control motor -V49- can be pulled in direction of -arrow B- out of ball head mounting -4-.

rrectness of i t to the co nform spec a t ion h re wit in t his

– Take right headlight range control motor -V49- out of headlight housing.

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Installing

Carry out installation in the reverse sequence, noting the follow‐ ing: – Carefully insert ball head -1- of hand headlight range control motor -V49- in ball head mounting -arrow-. Caution

When installing cover cap, ensure cap is seated correctly. The ingress of water will lead to permanent damage to the head‐ light. cop yri gh t . Co py i

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– Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work . Prote cted by

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228

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– Check headlight functions.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

1.5.3

Removing and installing headlight range Volkswagen AG does control motor (Visteon)olkswagen AG. no ss

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headlight adjustment must be checked and the headlights ad‐ justed ⇒ Maintenance ; Booklet 20.1 ; Description of work .

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♦ The illustrations show the renewal of the left headlight range

control motor -V48- for the left headlight. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing

– Remove headlight ⇒ page 215 .

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– Turn cover cap -1- in -direction of arrow- and remove.

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– Turn left headlight range control motor -V48- -1- in direction of -arrow-.

1. Headlights with halogen bulbs (up to MY2009)

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– Move left headlight range control motor -V48- so that ball head -2- of left headlight range control motor -V48- can be pulled in direction of -arrow- out of ball head cup -1-.

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– Pull off connector -1-.

– Take left headlight range control motor -V48- out of headlight housing. Installing

Carry out installation in the reverse sequence, noting the follow‐ ing:

Caution

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– Check headlight functions.

– Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

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When installing cover cap, ensure cap is seated correctly. The ingress of water will lead to permanent damage to the head‐ light.

thi sd o cu m en

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– Carefully insert ball head of left headlight range control motor -V48- -1- in ball head cup -arrow-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

1.6

Repairing headlight retaining tabs

If the upper headlight retaining tab -1-, the outer headlight retain‐ ing tab -2- or the lower headlight retaining tab -3- is damaged or has broken off, it can be replaced by installing the repair kit. There is no need to renew the entire headlight. Note ♦ Check that there is no further damage to the headlight that

would make installation of the repair kit unnecessary.

♦ Two different repair kits are available for the left and right

headlights ⇒ ETKA (electronic parts catalogue) .

♦ Each repair kit includes the upper, the outer and the lower

headlight retaining tabs, four screws, a panel nut (already fit‐ ted on the upper retaining tab), olkswagen AGbushes (one each . Vadjustment gen AG doetabs). already fitted on the lkouter s no swa and lower retaining

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Repairing lower retaining tab ⇒ page 232 . es, in part or in w l purpos hole ercia , is n m ot com

Repairing upper retaining tab Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

Procedure – Remove headlight ⇒ page 215 .

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– Remove existing headlight retaining tab -1- completely from headlight.

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1.6.1

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Repairing

o yV db ir se upper tho retaining tab ⇒ page 231 . au s s outer retaining tab ⇒ page 232 .

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1. Headlights with halogen bulbs (up to MY2009)

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231

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Form-fit the new retaining tab -2- on the base of the retaining tab on the headlight -4- and tighten the screw -3-. Note

The panel nut -1- is already pre-assembled on the new retaining tab -2-. – Install headlight ⇒ page 215 . – Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

1.6.2

Repairing outer retaining tab Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Procedure – Remove headlight ⇒ page 215 . . Volkswagcompletely – Remove existing headlight retaininggetab en AG AG-arrowdoes a n ksw from headlight. not Vol

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– Form-fit the new retaining tab -3- on the base of the retaining tab on the headlight -1- and tighten the screw -2-. Note

The adjustment bush -4- is already pre-assembled on the new retaining tab -3-. – Install headlight ⇒ page 215 .

Repairing lower retaining tab AG.

Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

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1.6.3

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– Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Procedure – Remove headlight ⇒ page 215 . – Remove existing headlight retaining tab -arrow- completely from headlight.

– Form-fit the new retaining tab -3- on the base of the retaining tab on the headlight -1- and tighten the screw -2-. – Now tighten the screw -5- on the rear side. Note

The adjustment bush -4- is already pre-assembled on the new retaining tab -3-. – Install headlight ⇒ page 215 .

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1.7

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– Check headlight settings and adjust ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

Converting headlights for use when driv‐ ing on the left or right Note

♦ To avoid dazzling oncoming traffic with asymmetrical lights,

both headlights should be converted to the direction of traffic (driving on the left or right) relevant to the country in which the vehicle is being driven.

♦ Conversion of the headlights is not designed as a permanent

conversion for other countries. It is only suitable as a „tourist solution“ for a short stay abroad.

AG.

♦ The information on „right“ and „left“ on the masking film always

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♦ Both headlights of a vehicle must always be converted.

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sections of film.

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♦ The corresponding headlight conversion set consists of two

relates to the direction of travel when looking forwards from inside the vehicle.

1. Headlights with halogen bulbs (up to MY2009)

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1.7.1

Converting headlights designed for driv‐ ing on the right to driving on the left

Note ♦ The headlight conversion set comprises two pieces of film. ♦ Please note the different part numbers for the headlight con‐

version sets from right to left-hand trafficAand rightkswagleft en Ato G. Volfrom G do agen hand traffic. es n lksw o Vo by

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ed converting. ♦ Clean headlight lens before ris

– Clean headlight lens. Left headlight:

– Remove protective film on back of assembly film -D- in area -C- only. – Align positioning film -D- with the bottom edge to line -B- on the lens of the headlight. – Align positioning film -D- at the same time with its radius to line -A- on the lens of the headlight. – Push down in area -C- on the headlight lens. – Carefully pull application film -D- off the lens of the headlight again. – The masking film -C- remains on the headlight lens. Right headlight:

– Remove protective film on back of assembly film -D- in area -C- only. cop yri gh t . Co py i

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– Align positioning film -D- at the same time with its radius to line -A- on the lens of the headlight. AG.

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– Push down in area -C- on the headlight lens. – Carefully pull application film -D- off the lens of the headlight again. – The masking film -C- remains on the headlight lens. Note ♦ Remove any remaining adhesive using alcohol-based or al‐

cohol and water-based cleaning fluid. For example, a cloth soaked with isopropyl alcohol

♦ Customers should be informed of how to remove residual ad‐

hesive after detaching the masking section.

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– Align positioning film -D- with the bottom edge to line -B- on the lens of the headlight.

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„0“.

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– Turn light switch to

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

1.7.2

Converting headlights designed for driv‐ ing on the left to driving on the right

Note ♦ The headlight conversion set comprises two pieces of film. ♦ Please note the different part numbers for the headlight con‐

version sets from right to left-hand traffic and from left to righthand traffic.

♦ Clean headlight lens before converting. ♦ Pull off adhesive film from headlight lens and remove residual

adhesive from headlight.

– Turn light switch to position „0“. – Clean headlight lens.

– Remove protective film on back of assembly film -D- in area -C- only. – Align positioning film -D- with the bottom edge to line -B- on the lens of the headlight. – Align positioning film -D- at the same time with its radius to line -A- on the lens of the headlight. – Push down in area -C- on the headlight lens.

– Carefully pull application film -D- off the lens of the headlight again. – The masking film -C- remains on the headlight lens. Right headlight:

– Remove protective film on back of assembly film -D- in area -C- only. – Align positioning film -D- with the bottom edge to line -B- on the lens of the headlight.

AG.

– Carefully pull application film -D- off the lens of the headlight again.

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– Push down in area -C- on the headlight lens.

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Left headlight:

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– The masking film -C- remains on the headlight lens. Note ♦ Remove any remaining adhesive using alcohol-based or al‐

cohol and water-based cleaning fluid. For example, a cloth soaked with isopropyl alcohol

♦ Customers should be informed of how to remove residual ad‐

hesive after detaching the masking section.

1.8

Adjusting headlights

– Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work . 1. Headlights with halogen bulbs (up to MY2009)

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2

Headlights with halogen bulbs (from MY2009)

2.1

General description Note

♦ Before working on headlights, always switch off the headlights

and remove the ignition key.

♦ When dealing with complaints, it is absolutely essential that

the function and operation of the lighting system are first un‐ n AG. Volkswagen AG do derstood. e wage

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⇒ Operating instructions

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The vehicle is fitted with headlights from two different manufac‐ turers: ♦ Valeo

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♦ Hella

Removal and installation of the headlights are the same except for removal and installation of the headlight range control motors and the cap behind the dipped beam bulb. Fault detection and fault display

The onboard supply control unit is equipped with self-diagnosis. For fault finding, use vehicle diagnosis, testing and information system -VAS 5051B- in „Guided fault finding“ mode.

Assembly overview

♦ The assembly overview shows both control motor variants of

headlight manufacturers Hella ⇒ Item 3 (page 237) and Valeo ⇒ Item 4 (page 237) since their removal and installation are different.

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♦ The assembly overview shows both cover-cap variants of

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2.2

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 1 - Cover cap 2 - Cover cap 3 - Cover cap ❑ Only manufacturer Hel‐ la ⇒ page 241 4 - Cover cap ❑ Only manufacturer Va‐ leo ⇒ page 241 5 - Left headlight range control motor -V48- / right headlight range control motor -V49❑ Manufacturer Hella ❑ Removing and installing ⇒ page 247

7 - Bulb holder with grip

8 - Left headlight dipped beam bulb -M29- / right headlight dip‐ ped beam bulb -M31❑ Bulb: H7 12 V/55 W ❑ Renewing ⇒ page 218

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9 - Headlight ❑ Removing and installing ⇒ page 238 ❑ Adjusting headlight in‐ stallation position ⇒ page 240 ❑ Repairing headlight securing tabs ⇒ page 251 ❑ Converting for driving on left/right ⇒ page 254 10 - Guide

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13 - Left headlight main beam bulb -M30- / right headlight main beam bulb -M32❑ Bulb: 12 V 15/55 W ❑ Renewing ⇒ page 220 agen lksw Vo by

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14 - Left side light bulb -M1- / right side light bulb -M3❑ Bulb: 12 V/5 W ❑ Renewing ⇒ page 222 15 - Bulb holder with grip 16 - Front left turn signal bulb -M5- / front right turn signal bulb -M7❑ Bulb: 12 V/24 W ❑ Renewing ⇒ page 223 17 - Bulb holder with grip

2. Headlights with halogen bulbs (from MY2009)

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

2.3

Removing and installing headlight

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-

Note ♦ You do not have to disconnect the earth wire of the battery -

A- .

♦ The vehicle is fitted with headlights from two different manu‐

facturers; removal and installation of both headlight versions are identical.

olkswagen AG ♦ Illustrations show removal and installation of the leftgheadlight. en AG. V d

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th ♦ Check headlight settings and adjustauheadlights if necessary

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing

– Remove the radiator grille ⇒ General body repairs, exterior; Rep. gr. 66 . – Remove front bumper cover ⇒ General body repairs, exterior; Rep. gr. 63 . – Release and disconnect multi-pin connector -1-. – Remove bolt -2- on inner part of headlight.

AG.

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Caution

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ss ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Unscrew the three bolts -arrows-. – Pull headlight forwards and straight out of body aperture. Installing Carry out installation in the reverse sequence, noting the follow‐ ing:

– Insert headlight with the three guides on underside into mount‐ ings -arrows- on guide and push into body aperture.

– First, screw in the three bolts -arrows-.

– Check headlight installation position is central, i.e. shut lines/ gaps are equal around headlight.

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– Tighten all threaded connections to specified torques ⇒ page 236 .

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– Then, screw in bolt -2- on rear of headlight.

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If the shut lines/gaps around the headlight are uneven, the instal‐ lation position must be adjusted ⇒ page 217 . – Check headlight functions. – Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

2. Headlights with halogen bulbs (from MY2009)

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2.4

Adjusting headlight installation position Note

♦

If it transpires during checking of the installation position that the shut lines/gaps between headlight and body are uneven, the in‐ stallation position must be adjusted. – Switch off ignition and all electrical consumers and remove ignition key. – Remove the radiator grille ⇒ General body repairs, exterior; Rep. gr. 66 . – Loosen bolt -2- on rear of headlight.

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– Loosen screw -arrow- at bottom of headlight.

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– Loosen the three bolts -arrows-.

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AG. Volkswagen AG d agen oes ksw not l o V gthe ua front by To adjust the installation position of the headlight, d ran e s i not have to be removed. tee r bumper does o h t or u ac a The illustrations show the left headlight. ss

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Adjust shut lines/gaps to body by pushing in or pulling out alignment bush -arrow- on headlight. – Tighten all threaded connections to specified torques ⇒ page 236 . – Check and readjust headlight to ensure gaps are even all round. – Install the radiator grille ⇒ General body repairs, exterior; Rep. gr. 66 . – Check headlight functions. – Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

2.5

Renewing bulbs

2.5.1

Renewing headlight dipped beam bulb

Note ♦ The headlight does not have to be removed to change the

bulb.

. Volkswagen AG gen AG does swa

k not ♦ The diagrams dipped beam Vol show renewal of the left headlight gu by ed bulb -M29for the left headlight. ris

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ara nte e

Caution

♦ Switch off ignition and all electrical consumers.

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♦ Remove the ignition key.

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tho au s s

Removing Only headlight manufacturer Hella: – Remove cover cap -1-. Only headlight manufacturer Valeo: Note

♦ For reasons of clarity, headlight is shown removed in the fol‐

lowing illustrations. bulb.

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2. Headlights with halogen bulbs (from MY2009)

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241

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull clip -1- upwards and remove cover cap -2- from rear of headlight. Continuation for all vehicles:

– Turn bulb holder with left headlight dipped beam bulb -M29in direction of -arrow- and remove from headlight.

– Pull left headlight dipped beam bulb -M29- -2- in -direction of arrow- out of bulb holder -1-. Bulb: 12 V/55 W Installing Caution

AG. Volkswagen AG d agen oes ksw not l o V gu y ara db nte ir se o eo h t u ra a c Fingers ss

♦ When installing cover cap, ensure that it seats properly. The ingress of water will lead to permanent damage to the headlight. – Check headlight functions.

– Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

AG.

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♦ Do not touch glass envelope when fitting bulb. leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

2.5.2

Renewing main headlight bulb/daytime running light

Note ♦ The left main beam headlight bulb -M30- / right main beam

headlight bulb -M32- is a twin filament bulb and assumes si‐ multaneously the function of the left daytime running light L174- / right daytime running light -L175- .

♦ The headlight does not have to be removed to change the

bulb.

♦ The illustrations show the renewal of the left headlight main

beam bulb -M30- / left daytime running light bulb -L174- for the left headlight. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r eo ho t u ra a c ss

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r fo ng

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– Remove cover cap -1-.

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2. Headlights with halogen bulbs (from MY2009)

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Turn bulb holder -1- in direction of -arrow- and pull it out of headlight together with left headlight main beam -M30- / left daytime running light bulb -L174- . Note

The left headlight main beam bulb -M30- / left daytime running light bulb -L174- is permanently attached to the bulb holder and cannot be renewed separately. Bulb: 12 V 15/55 W Installing Caution

♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over. ♦ When installing cover cap, ensure that it seats properly. The ingress of water will lead to permanent damage to the headlight. AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r o eo h t u ra c sa s necessary

Carry out installation in the reverse sequence, noting the follow‐ ing: – Check headlight functions.

Note

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e g n

Renewing side light bulb

♦ The headlight does not have to be removed to change the

bulb.

♦ The diagrams show renewal of the left side light bulb -M1- for

the left headlight. Caution

♦ Switch off ignition and all electrical consumers.

Prote cted by

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244

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♦ Remove the ignition key.

rrectness of i t to the co nform spec atio h re n wit i n thi sd o c um en

2.5.3

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– Check headlight settings and adjust headlights if ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Removing – Remove cover cap -1-.

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–

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– Pull left side light bulb -M1- -2- in -direction of arrow- out of bulb holder -1-. Bulb: wedge-base bulb 12 V/5 W Installing

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ng

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♦ When installing cover cap, ensure that it seats properly. The ingress of water will lead to permanent damage to the headlight.

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♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over.

thi sd o cu m en

Caution

AG.

Carry out installation in the reverse sequence, noting the follow‐ ing: – Check headlight functions.

2.5.4

Renewing front turn signal bulb

Note ♦ The headlight does not have to be removed to change the

bulb.

♦ The illustrations show the renewal of the front left turn signal

bulb -M5- for the left headlight.

2. Headlights with halogen bulbs (from MY2009)

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Remove cover cap -1-.

– Turn bulb holder -1- in direction of -arrow- and pull left front turn signal bulb -M5- backwards out of headlight.

AG.

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Rep. gr.94 - Lights, bulbs, switches - exterior

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246

rrectness of i t to the co nform spec a t i h re o n in wit thi sd o cu m en

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e g n

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AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r o eo h t u ra a c ss

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Press lock button -arrow- and pull left front turn signal bulb M5- -1- upwards out of bulb holder. Note

The left front turn signal bulb -M5- is permanently attached to the bulb holder and cannot be dismantled. Bulb: 12 V/24 W Installing Caution

♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over. ♦ When installing cover cap, ensure that it seats properly. The ingress of water will lead to permanent damage to the headlight. Carry out installation in the reverse sequence, noting the follow‐ ing: Note ♦ To lock the bulb holder, there are two locking lugs of different

lengths in the reflector.

♦ Insert bulb holder together with left front turn signal bulb -M5-

into reflector so that the longer locking lug points upwards.

– Check headlight functions.

Removing and installing headlight range control motor

2.6.1

Removing and installing (Hella)

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Note

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm te o a itte ir v du p or nl f e ng

2.6

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AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h t u ra a c ss

♦ If control motors are removed and reinstalled or renewed, the

headlight adjustment must be checked and the headlights ad‐ justed ⇒ Maintenance ; Booklet 20.1 ; Description of work .

♦ The illustrations show the renewal of the left headlight range

control motor -V48- for the left headlight.

♦ The renewal of the headlight range control motor -V49- for the

right headlight is carried out in the same way.

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AG.

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♦ Remove the ignition key.

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♦ Switch off ignition and all electrical consumers.

do c um en

Caution

2. Headlights with halogen bulbs (from MY2009)

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247

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Removing – Remove headlight ⇒ page 215 . – Remove cover cap -1-.

– Detach connector -1- from left headlight range control motor 2 -V48- .

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t a itte riv du p r o nl f e ng

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– Turn left headlight range control motor -V48- -1- in direction of -arrow- to stop and pull it slightly backwards out of mounting -2-.

rrectness of i t to the co nform spec a t ion h re wit in t his

– Tilt left headlight range control motor -V48- -1- so that ball head -3- can be swivelled downwards out of the head mount‐ ing -2-.

– Install left headlight range control motor -V48- into headlight.

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AG.

– Reconnect connector.

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Carry out installation in the reverse sequence, noting the follow‐ ing:

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Installing

do c um en

– Take left headlight range control motor -V48- out of headlight housing.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Carefully swivel ball head -3- from below in ball head mounting -2-. – Lock left headlight range control motor -V48- -1- by turning it anti-clockwise to stop. Caution

When installing cover cap, ensure cap is seated correctly. The ingress of water will lead to permanent damage to the head‐ light. – Check headlight functions. – Adjust headlights. – Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

2.6.2

Removing and installing (Valeo)

Note

♦

AG. Volkswagen AG d agen oes ksw not l o V gu y If control motors are removed and reinstalled or renewed, the b ara ed nte s i r headlight adjustment must be checked and the headlights ad‐ o eo h t ra justed ⇒ Maintenance ; Bookletau 20.1 ; Description of work . c ss

trol motor -V49- on the right headlight.

♦ The renewal of the left headlight range control motor -V48- for

the left headlight is carried out in the same way. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing

– Remove headlight ⇒ page 215 . – Pull clip -1- upwards and remove cover cap -2- from rear of headlight.

rrectness of i t to the co nform spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e g n

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♦ The illustrations show the renewal of the headlight range con‐

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2. Headlights with halogen bulbs (from MY2009)

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249

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Turn adjuster screw -1- for vertical adjustment of dipped beam headlight completely in the following direction: ♦ Left headlight - anti-clockwise ♦ Right headlight – clockwise – Then lift adjuster screw -1- slightly with a suitable screwdriver and pull it upwards out of headlight housing. – Disconnect connector -2- from right headlight range control motor -V49- .

– Swivel right headlight range control motor -V49- -1- to unlock in direction of -arrow- to stop.

– Tilt right headlight range control motor -V49- -3- so that ball head -1- can be swivelled upwards out of ball head mounting -2-. – Take right headlight range control motor -V49- out of headlight housing. Installing

. Volkswagen AG gen AG d

a oes Carry out installation in the reverseVosequence, noting the follow‐ not lksw gu y b ara ing: d e is or

th control motor -V49- into headlight. – Install right headlight range au es, in part or in w l purpos hole ercia , is n m m ot p r co erm o e t a itte v i r du p or nl f e ng

– Lock right headlight range control motor -V49- -3- by turning it anti-clockwise to stop. Note

When inserting adjuster screw for vertical adjustment of dipped beam headlight, ensure that O-ring is present and in the right po‐ sition. – Insert adjuster screw for vertical adjustment of dipped beam headlight in headlight housing again. Caution

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Rep. gr.94 - Lights, bulbs, switches - exterior

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250

ht rig py Co t.

When installing cover cap, ensure cap is seated correctly. The ingress of water will lead to permanent damage to the head‐ light.

rrectness of i t to the co nform spec at i h re o n wit in t his d o cu m en

– Carefully swivel ball head -1- from above in ball head mounting -2-.

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ss

– Reconnect connector.

nte eo ra c

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Fit cover cap -2- and secure it with strap -1-. – Check headlight functions. – Adjust headlights. – Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

n AG. Volkswagen AG do es n wage ot g olks V ua by d ran ir se tee o h t or ac au s s

Repairing headlight securing tabs urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t a itte riv du p r o nl f e ng

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2.7

If one or more headlight retaining tabs are damaged or broken off, they can be renewed by installing the repair kit. There is no need to renew the entire headlight.

rrectness of i t to the co nform spec a t ion h re wit in t his

Overview of installation locations of repair tabs 1-

Outer repair tab

2-

Centre repair tab

3-

Inner repair tab Note

♦ Check that there is no further damage to the headlight that

would make installation of the repair kit unnecessary.

♦ Two different repair kits are available for the left and right

headlights ⇒ ETKA (electronic parts catalogue) . Prote cted by c o py rig ht . C op yi

♦ The following illustrations show the repair of the retaining tabs AG.

Repairing outer retaining tab ⇒ page 251 .

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on the right headlight. Repairs on the right headlight are car‐ ried out in the same way.

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headlight retaining tab and the associated bolts/screws.

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♦ Each repair kit includes the outer, the centre and the inner

Repairing centre retaining tab ⇒ page 252 . Repairing inner retaining tab ⇒ page 253 .

2.7.1

Repairing outer retaining tab

Special tools and workshop equipment required ♦ Torque screwdriver -V.A.G 1624-

2. Headlights with halogen bulbs (from MY2009)

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Procedure – Remove headlight ⇒ page 215 . – Remove remains of old headlight retaining tab -1-.

– Form-fit new retaining tab -1- on base of retaining tab at head‐ light and tighten bolt -2- to 1.0 Nm.

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara ed nte s i and adjust headlights if necessary r o eo h t u ra 20.1 ; Descriptions of work . a c ss

– Install headlight ⇒ page 215 .

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Repairing centre retaining tab

Special tools and workshop equipment required

♦ Remove the ignition key.

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AG.

♦ Switch off ignition and all electrical consumers.

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Caution

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♦ Torque screwdriver -V.A.G 1624-

rrectness of i t to the co nform spec at i h re o n wit in t his d o cu m en

2.7.2

es, in part or in w l purpos hole ercia , is n m m ot p r co erm o e t a itte v i r du p or nl f e ng

– Check headlight settings ⇒ Maintenance ; Booklet

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Procedure – Remove headlight ⇒ page 215 . – Remove remains of old headlight retaining tab -1-.

– Form-fit new retaining tab -1- on base of retaining tab at head‐ light and tighten bolt -2- to 1.0 Nm. – Install headlight ⇒ page 215 . – Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t a itte riv du p r o nl f e ng

Repairing inner retaining tab

rrectness of i t to the co nform spec a t ion h re wit in t his

2.7.3

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AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r o eo h t u ra a c ss

Special tools and workshop equipment required ♦ Torque screwdriver -V.A.G 1624-

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♦ Remove the ignition key.

ht rig py Co t.

♦ Switch off ignition and all electrical consumers.

do c um en

Caution

Procedure – Remove headlight ⇒ page 215 .

2. Headlights with halogen bulbs (from MY2009)

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253

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove remains of old headlight retaining tab -1-.

– Form-fit new retaining tab -1- on base of retaining tab at head‐ light and tighten bolt -2- to 1.0 Nm. – Install headlight ⇒ page 215 . – Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

AG. Volkswagen AG d agen o

2.8

es n w otdriv‐ olks Converting for use when Vheadlights gu by ara d e nte s ing onhothe left or right ri e

♦ To avoid dazzling oncoming traffic with asymmetrical lights,

both headlights should be converted to the direction of traffic (driving on the left or right) relevant to the country in which the vehicle is being driven.

♦ The corresponding headlight conversion set consists of two

sections of film.

♦ Conversion of the headlights is not designed as a permanent

conversion for other countries. It is only suitable as a „tourist solution“ for a short stay abroad.

♦ Both headlights of a vehicle must always be converted. ♦ The details „right“ and „left“ on the masking film always refer

to the direction of travel when looking forwards from inside the vehicle.

AG.

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254

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es, in part or in w l purpos hole ercia , is n m m ot p r co erm o e t a itte v i r du p or nl f e g n

Note

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

2.8.1

Converting headlights designed for driv‐ ing on the right to driving on the left

Note ♦ The headlight conversion set comprises two pieces of film. ♦ Please note the different part numbers for the headlight con‐

version sets from right to left-hand traffic and from left to righthand traffic.

♦ Clean headlight lens before converting.

ility ab y li an pt ce

Procedure

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♦

AG. Volkswagen AG d agen oes ksw not l o V gu byremove re‐ ara After pulling off adhesive film from headlight lens, d nte ir se sidual adhesive from headlight lens. o eo h t u ra a c ss

– Turn light switch to position „0“. Left headlight:

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– Clean headlight lens.

– Remove protective film on back of assembly film -D- in area -C- only. – Align top and bottom of assembly film -D- with upper and lower edge -A- of headlight lens. – Align assembly film -D- simultaneously with line -B- on line of headlight lens. – Push down in area -C- on headlight lens. – Carefully pull assembly film -D- off headlight lens again. – Masking film -C- remains on headlight lens.

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Right headlight:

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2. Headlights with halogen bulbs (from MY2009)

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255

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove protective film on back of assembly film -D- in area -C- only. – Align top and bottom of assembly film -D- with upper and lower edge -A- of headlight lens. – Align assembly film -D- simultaneously with line -B- on line of headlight lens. – Push down in area -C- on headlight lens. – Carefully pull assembly film -D- off headlight lens again. – Masking film -C- remains on headlight lens. Note ♦ Remove any remaining adhesive using

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cohol and water-based cleaning fluid. For example a cloth soaked with isopropyl alcohol.

♦ Customers should be informed of how to remove residual ad‐

2.8.2

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hesive after detaching the masking section.

Converting headlights designed for driv‐ ing on the left to driving on the right

Note

♦ The headlight conversion set comprises two pieces of film. ♦ Please note the different part numbers for the headlight con‐

version sets from right to left-hand traffic and from left to righthand traffic.

♦ After pulling off adhesive film from headlight lens, remove re‐

256

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AG.

– Clean headlight lens.

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– Turn light switch to position „0“.

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♦ Clean headlight lens before converting.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Left headlight: – Remove protective film on back of assembly film -D- in area -C- only. – Align top and bottom of assembly film -D- with upper and lower edge -A- of headlight lens. – Align assembly film -D- simultaneously with line -B- on line of headlight lens. – Push down in area -C- on headlight lens. – Carefully pull assembly film -D- off headlight lens again. – Masking film -C- remains on headlight lens. Right headlight:

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– Push down in area -C- on headlight lens.

– Carefully pull assembly film -D- off headlight lens again. – Masking film -C- remains on headlight lens. Note

♦ Remove any remaining adhesive using alcohol-based or al‐

cohol and water-based cleaning fluid. For example a cloth soaked with isopropyl alcohol.

♦ Customers should be informed of how to remove residual ad‐

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Adjust headlight with halogen bulbs ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

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257

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

3

Headlights with gas discharge bulbs (up to MY2009) Note

♦ Before working on headlights with gas discharge bulbs, al‐

ways switch off headlights and remove ignition key.

♦ The automatic headlight range control on headlights with gas

discharge bulbs is equipped with self-diagnosis.

♦ When dealing with complaints, it is absolutely necessary to

understand the functions and the operation of the lighting sys‐ tem ⇒ Operating instructions .

♦ Additional information ⇒ Current flow diagrams, Electrical fault

finding and Fitting locations.

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3.1

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WARNING

♦ Never change bulbs if you are not familiar with the appro‐ priate procedures, safety precautions and tools. – If repairs are to be made to the headlights with gas discharge bulbs, observe the following: ♦ Notes on dangerous high voltage/currents ⇒ page 258 ♦ Notes on pressure/temperature/radiation/arcs ⇒ page 259 ♦ Assembly notes for gas discharge bulbs ⇒ page 260 ♦ Disposal regulations for gas discharge bulbs ⇒ page 260 Special tools and workshop equipment required ♦ Gloves

Notes on dangerous high voltage/currents

Control units for light systems, connectors and components pertaining to bulb holders conduct lethally high voltage.

AG.

Operating the control unit and the starter unit is permitted only with the bulb fitted.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 WARNING

•

When working on headlight system, ensure that there is no voltage in any components, including the dissipation of residual voltage after the headlights are switched off.

•

Residual voltage can be dissipated by turning the dipped beams on and then off again after withdrawing the ignition key.

•

When working on the headlight system, ensure that the lights cannot be switched on.

Notes on pressure/temperature/radiation/arcs WARNING

♦ Within the glass envelope of a gas discharge bulb, pres‐ sure can range from between 7 bar (cold) and 100 bar (hot). Temperatures can reach up to 700 degrees Celsius on the glass bulb.

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♦ Always wear safety goggles and gloves when removing and installing gas discharge bulbs!

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Switch off ignition and move ignition key.

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WARNING

•

The bulbs may be operated in the headlight housing only (protection against contact due to very hot bulbs, absorp‐ tion of UV radiation, avoidance of dazzling light, protection against explosion).

•

The glass envelope of the bulbs can be very hot - danger of burns!

•

Avoid looking directly into the beam, as the UV rays from the gas discharge bulb are about 2.5 times greater than normal halogen bulbs.

•

Avoid looking into the light beam (danger of glare); vision may be impaired for a substantial time.

WARNING

•

Avoid contact with burst glass envelopes.

•

H7 bulbs and gas discharge bulbs (xenon and bi-xenon) are under pressure and can explode while being changed - danger of injury.

•

Always wear safety goggles and gloves when removing and installing gas discharge bulbs!

3. Headlights with gas discharge bulbs (up to MY2009)

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259

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Repair notes for gas discharge bulbs Caution

♦ Before renewing a bulb, always switch off the concerned electrical consumer. ♦ Switch off ignition and all electrical consumers and re‐ move ignition key. ♦ Do not touch the glass envelope with bare fingers; use a clean cloth glove. When the light bulb is switched on, the heat would vaporise the oil of the finger prints which would then settle on the reflector, impairing the brightness of the headlight. ♦ A light bulb must always be renewed with a bulb of the same sort. The designation appears on the base of the bulb or on the glass envelope. ♦ Properly engage connector during installation and ensure tight seating of the connection. Disposal regulations for gas discharge bulbs WARNING

•

Gas discharge bulbs must be disposed of as hazardous waste; never dispose of gas discharge bulbs via house‐ hold waste system.

•

Gas discharge bulbs contain metallic mercury (Hg) and traces of thallium; never destroy these bulbs.

•

These components must be recycled in the correct man‐ ner according to national law.

•

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260

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

3.2

Assembly overview Note

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After any measures which could affect the headlight setting, the headlight setting must be checked and the headlights adjusted ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work . rrectness of i t to the co nform spec a t i h re o n in wit thi s

1 - Vent hose ❑ On headlight

2 - Left headlight range control motor -V48- / right headlight range control motor -V49❑ Manufacturer AL (Auto‐ motive Lighting) 3 - Bolt ❑ 2 Nm

4 - Cover cap

5 - Starter unit for gas dis‐ charge bulbs -N195-

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7 - Left gas discharge (xenon) bulb -L13- / right gas discharge (xenon) bulb -L14❑ Type: D2S 35 W ❑ Notes on safety ⇒ page 258 ❑ Renewing ⇒ page 262

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6 - Bulb retainer

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8 - Bolt ❑ 4 Nm 9 - Headlight ❑ Removing and installing ⇒ page 215 ❑ Adjusting headlight in‐ stallation position ⇒ page 217 ❑ Repairing headlight se‐ curing tabs ⇒ page 276 ❑ Converting for driving on left/right ⇒ page 277 10 - Control unit for headlight range control -J431❑ Removing and installing ⇒ page 272 ❑ Coding ⇒ page 274 11 - Front left vehicle level sender -G78❑ Removing and installing ⇒ page 275 ❑ Checking ⇒ page 275 12 - Rear left vehicle level sender -G76❑ Removing and installing ⇒ page 275 ❑ Checking ⇒ page 275 13 - Adjustment bush ❑ Adjusting headlight installation position ⇒ page 217 3. Headlights with gas discharge bulbs (up to MY2009)

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261

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 14 - Bolt ❑ 4 Nm 15 - Left gas discharge bulb control unit -J343- / right gas discharge bulb control unit -J344❑ Not capable of self-diagnosis ❑ Removing and installing ⇒ page 271 16 - Bolt ❑ 2 Nm 17 - Left headlight main beam bulb -M30- / right headlight main beam bulb -M32❑ Bulb: H7U 12 V/55 W ❑ Renewing ⇒ page 264 18 - Front left turn signal bulb -M5- / front right turn signal bulb -M7❑ Bulb: H2 WLL 12 V/21 W ❑ Renewing ⇒ page 267 19 - Left side light bulb -M1- / right side light bulb -M3❑ Bulb: W 12 V/5 W ❑ Renewing ⇒ page 266 20 - Cover cap 21 - Cover cap

3.3

Removing and installing headlight

Removing and installing headlights ⇒ page 215 . Observe safety notes for gas discharge

Adjusting headlight installation position

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3.4

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Adjusting headlight installation position ⇒ page 217 .

Renewing bulbs

3.5.1

Renewing gas discharge bulb

Note

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3.5

The diagrams show renewal of left gas discharge (xenon) bulb L13- for the left headlight. Caution

♦ Switch off ignition and all electrical consumers.

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262

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– Remove headlight ⇒ page 262 .

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Removing

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♦ Observe safety notes for gas discharge bulbs ⇒ page 258 .

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♦ Remove the ignition key.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Turn cover cap -1- in -direction of arrow- and remove.

– Pull off connector -1-. Note

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The connector is ejected automatically when the gas discharge bulb starter unit -N195- is removed.

♦ In the bulb glass of the left gas discharge bulb -L13- , pressures can range from between 7 bar (cold) and 100 bar (hot). Temperatures can reach up to 700 degrees Cel‐ sius on the glass bulb. ♦ Should the glass envelope explode, there is a risk of injury from burning. ♦ Always wear safety goggles and gloves when removing and installing left gas discharge (xenon) bulb -L13- .

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– Turn bulb retainer -1- in direction of -arrow- and remove bulb retainer.

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– Turn gas discharge light starter unit -N195- -1- in direction of lettering „OPEN“ and pull gas discharge light starter unit N195- off headlight.

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3. Headlights with gas discharge bulbs (up to MY2009)

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263

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Carefully pull left gas discharge (xenon) bulb -L13- -1- out of mounting. Installing Caution

♦ Do not touch glass envelope when fitting right gas dis‐ charge (xenon) bulb -L13- . Fingers leave traces of grease on the glass envelope, which evaporate when the left gas discharge (xenon) bulb -L13- is switched on and cause the glass envelope to cloud over. ♦ Ensure glass envelope of left gas discharge (xenon) bulb -L13- is not stressed mechanically. The glass envelope is extremely sensitive and is also under a high internal pres‐ sure. ♦ Avoid looking directly into the collimated beam as the UV radiation from the left gas discharge (xenon) bulb -L13- is about 2.5 times higher than from normal halogen bulbs. ♦ When installing cover cap, ensure that it seats properly. The ingress of water will lead to permanent damage to the headlight. . Volkswagen AG gen AG does not gu ara nte eo ra c

wa Carry out installation in the reverse sequence, notingVthe olks follow‐ y b ing: ed

– Check headlight functions.

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– Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

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If a headlight with automatic range control is removed, the basic setting of the headlights is always to be checked after installation ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

Renewing headlight main beam bulb

Note

Caution

♦ Switch off ignition and all electrical consumers. ng

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The following diagrams show renewal of the left headlight main beam bulb -M30- for the left headlight.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Removing – Remove cover cap -1-.

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– Pull off connector -arrow-.

– Push retaining clip -2- in -direction of arrow- under locking lugs -1- and lift up retaining clip -2-.

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Installing

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– Take left headlight main beam bulb -M30- -1- out of headlight.

Caution

♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over. ♦ When installing cover cap, ensure that it seats properly. The ingress of water will lead to permanent damage to the headlight. Carry out installation in the reverse sequence, noting the follow‐ ing:

3. Headlights with gas discharge bulbs (up to MY2009)

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265

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Place left headlight main beam bulb -M30- -1- in recesses -arrows- of headlight. – Check headlight functions. – Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

3.5.3

Renewing side light bulb

Note

The following diagrams show renewal of the left side light bulb M1- of the left headlight. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Remove cover cap -1-.

– Pull bulb holder -2- with left side light bulb -M1- out of reflector -1- (be careful not to stretch wiring).

AG.

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Rep. gr.94 - Lights, bulbs, switches - exterior

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266

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull left side light bulb -M1- -2- in -direction of arrow- out of bulb holder -1-. Installing Caution

♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over. ♦ When installing cover cap, ensure that it seats properly. The ingress of water will lead to permanent damage to the headlight. Carry out installation in the reverse sequence, noting the follow‐ ing: – Check headlight functions. – Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

3.5.4

Renewing front turn signal bulb

Note

The following diagrams show the renewal of the front left turn sig‐ nal bulb -M5- for the left headlight. Caution

♦ Switch off ignition and all electrical nconsumers. AG. Volkswagen AG ge swa

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– Remove cover cap -1-.

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3. Headlights with gas discharge bulbs (up to MY2009)

267

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Turn bulb holder -1- with front left turn signal bulb -M5- in -direction of arrow- and remove from reflector (be careful not n AG. Volkswagen AG do to stretch wiring). es wage

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– Push front left turn signal bulb -M5- -2- down in bulb holder -1- and turn front left turn signal bulb -M5- -2- in -direction of arrow-. – Pull front left turn signal bulb -M5- -2- out of bulb holder -1-. Installing

Caution

♦ When installing cover cap, ensure that it seats properly. The ingress of water will lead to permanent damage to the headlight.

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Carry out installation in the reverse sequence, noting the follow‐ ing: – Check headlight functions. – Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

3.6

Removing and installing headlight range control motor Note

♦ If control motors are removed and reinstalled or renewed, the

headlight adjustment must be checked and the headlights ad‐ justed ⇒ Maintenance ; Booklet 20.1 ; Description of work .

♦ The illustrations show the renewal of the left headlight range

control motor -V48- for the left headlight. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Remove headlight ⇒ page 262 .

268

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♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Turn cover cap -1- in -direction of arrow- and remove. Note

– Press and turn the plastic hexagon out of the headlight hous‐ ing to break open the assembly opening. Note

The broken open sealing piece must not remain in the headlight. Remove it from the headlight housing. – Turn gas discharge light starter unit -N195- -1- in direction of starter unit lettering „OPEN“ onto stop. ht rig py Co t.

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– Fit a socket -1- on the plastic hexagon on the back of the headlight housing.

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This opening must be sealed on completion of repairs with sep‐ arately available sealing plug.

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– Pull off gas discharge light starter unit -N195- straight back‐ wards from headlight

3. Headlights with gas discharge bulbs (up to MY2009)

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269

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove both bolts -arrows- for headlight range control unit .

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– Lower the reflector in the headlight again, lift the left headlight range control motor -V48- -1- slightly and turn it in -direction of arrow-. – Take the left headlight range control motor -V48- out of the headlight housing as far as the connected wiring allows.

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AG.

270

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Carry out installation in the reverse sequence, noting the follow‐ ing:

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– Disconnect connection -2- and remove left headlight range control motor -V48- -1-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Reconnect connector -2- on headlight range control motor -1-.

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– Insert left headlight range control motor -V48- -1- in headlight in position as shown in illustration. – Lift dipped beam reflector in headlight slightly and turn the ball head -2- of the left headlight range control motor -V48- so that it can be pushed into the ball head mounting -3- in -direction of arrow-. – Screw in both bolts for left headlight range control motor V48- . Caution

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– Tighten all threaded connections to specified torques ⇒ page 261 . agen lksw Vo by

– Install gas discharge light starter unit -N195- and screw on the cap. AG.

– Seal the broken-open assembly openings -1- using a sepa‐ rately ordered sealing plug ⇒ ETKA (electronic parts cata‐ logue) . – Check headlight functions. – Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

3.7

Removing and installing gas discharge light control unit Note

♦ Left gas discharge bulb control unit -J343- / right gas discharge

bulb control unit -J344- is not capable of self-diagnosis.

♦ The illustrations show renewal of the left gas discharge bulb

control unit -J343- on the left-hand headlight.

3. Headlights with gas discharge bulbs (up to MY2009)

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Remove headlight ⇒ page 262 . – Unscrew bolts -arrows- of left gas discharge bulb control unit -J343- -1-. Note

Installing

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– Remove left gas discharge bulb control unit -J343- -1- from headlight.

Caution

Ensure that the seal is seated correctly when installing the left gas discharge bulb control unit -J343- . The ingress of water will lead to permanent damage to the headlight. Carry out installation in the reverse sequence, noting the follow‐ ing: – Tighten all threaded connections to specified torques ⇒ page 261 . – Check headlight functions. cop yri gh t . Co py i

3.8

Control unit for headlight range control J431-

3.8.1

Removing and installing control unit for headlight range control -J431-

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272

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Special tools and workshop equipment required

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– Carry out headlight basic setting ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

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AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e For removal of the left gas discharge bulb control unit -J343, nte is r o eo h there is no need to removeutany connectors. The connector is fixed ra a c on the headlight and is automatically separated when the left gas ss

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Removal wedge -VAS 3409-

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moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape.

Removing

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– Remove side cover -1- of dash panel by inserting removal wedge -VAS 3409- or a suitable screwdriver in recess -2- and levering off side cover -1- in direction of -arrow-.

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– Release retaining clip -1- in direction -arrow- and pull connec‐ tor -2- off control unit for headlight range control -J431- .

3. Headlights with gas discharge bulbs (up to MY2009)

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273

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Unscrew bolt -arrow- and take control unit for headlight range control -J431- -1- off bracket -2-. Installing Carry out installation in the reverse sequence, noting the follow‐ ing:

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– Tighten all threaded connections to specified torques ⇒ page 261 . After installing a new headlight range control control unit -J431- , the control unit must be coded ⇒ page 274 .

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Coding control unit for headlight range control -J431Prote cted by

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274

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3.8.2

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– Lock the connector -1- by pressing retaining clip -2- in direction of -arrow-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

– Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body

♦ Electrical system

♦ 01 - On Board Diagnosis capable systems ♦ Automatic headlight range control ♦ Automatic headlight range control functions ♦ Coding automatic headlight range control

Vehicle level sender

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Once the control unit for headlight range control -J431- has been coded, a headlight basic setting must be carried out ⇒ Mainte‐ nance ; Booklet 20.1 ; Descriptions of work .

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There is a front left vehicle level sender -G78- located on the front axle and a rear left vehicle level sender -G76- on the rear axle. AG.

If front left vehicle level sender -G78- / rear left vehicle level send‐ er -G76- is renewed, check values ⇒ page 275 and carry out basic setting of headlights ⇒ Maintenance ; Booklet 20.1 ; De‐ scriptions of work . If the values from front left vehicle level sender -G78- / rear left vehicle level sender -G76- are outside the specified tolerance, basic headlight setting cannot be carried out.

3.9.1

Removing and installing vehicle level sender

The vehicle level senders are part of the adaptive suspension system. Removal and installation of vehicle level sender ⇒ Run‐ ning gear, axles, steering; Rep. gr. 43 .

3.9.2

Checking vehicle level sender

Special tools and workshop equipment required

3. Headlights with gas discharge bulbs (up to MY2009)

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275

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

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The front left vehicle level sender -G78- / sender -G76- transmit the longitudinal inclination angle of the ve‐ hicle by way of signals to the control unit for headlight range control -J431- .

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A check is made as to whether the rear left vehicle level sender G76- / front left vehicle level sender -G78- supply the control unit for headlight range control -J431- with plausible signals. No entry is stored in the control unit for cornering light and head‐ light range control -J431- in the following instances: ♦ In the case of incorrectly installed front left vehicle level sender -G78- / rear left vehicle level sender -G76♦ For mechanical damage to front left vehicle level sender G78- / rear left vehicle level sender -G76♦ Vehicle suspension has been modified (lowered).

Prote cted by

– In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system ♦ 01 - On Board Diagnosis capable systems ♦ Automatic headlight range control ♦ Automatic headlight range control functions ♦ Checking vehicle level sender

3.10

Repairing headlight securing tabs

Repairing headlight securing tabs ⇒ page 231 .

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AG.

– Connect vehicle diagnosis, testing and information system VAS 5051B- .

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Procedure

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If the values from front left vehicle level sender -G78- / rear left vehicle level sender -G76- are outside the specified tolerance, basic headlight setting cannot be carried out.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

3.11

Converting headlights for use when driv‐ ing on the left or right

To avoid dazzling oncoming traffic with the asymmetrical lights, both headlights should be converted (driving on the left or right) for the country in which the vehicle is being driven. Note ♦ Before working on gas discharge headlights, always switch off

the headlights and remove the ignition key.

♦ The procedure for converting the headlights is the same for

both sides and is described as follows using the left headlight as an example.

Procedure – Remove headlight ⇒ page 262 .

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– Turn cover cap -1- in -direction of arrow- and remove.

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WARNING urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t a itte v i r d p

♦ There is a risk of injury from burning.

♦ Always allow the headlight to cool for a sufficient period of time. – Push control lever -1- in desired position - A- or -B-. Control lever -1- up: driving on left -A-

Control lever -1- down: driving on right -B-

r fo ng

When installing cover cap, ensure cap is seated correctly. The ingress of water will lead to permanent damage to the head‐ light.

AG.

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– Install headlight ⇒ page 262 .

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– Seal headlight housing using cover cap and secure in place by applying twisting motion.

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Caution

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♦ Within the glass envelope of a gas discharge bulb, pres‐ sure can range from between 7 bar (cold) and 100 bar (hot). Temperatures can reach up to 700 degrees Celsius on the glass bulb. The reflector is equally as hot.

– Check headlight functions. – Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

3.12

Adjusting headlights

Adjusting headlights with gas discharge bulb ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

3. Headlights with gas discharge bulbs (up to MY2009)

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277

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

4

Headlights with gas discharge bulbs and cornering lights (from MY2010)

4.1

General description Note

♦ Before working on headlight with gas discharge lights and cor‐

nering lights, always switch off the headlights and remove the ignition key.

♦ When dealing with complaints, it is absolutely essential that

the function and operation of the lighting system are first un‐ derstood.

♦ Additional information: ⇒ Operating instructions ⇒ Self-study programme No. 335 ; The Cornering Light System ⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐ tions Observe safety notes for gas discharge bulbs ⇒ page 258 . General description The headlights with gas discharge bulbs and a have a „bi-xenon“ feature.

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With conventional xenon headlights, the gas discharge bulbs only generate the dipped beam. The „bi-xenon“ features makes it pos‐ sible to generate both the dipped beam and the main beam with „one“ gas discharge bulb. To achieve this, an electromechanical adjuster ( left headlight screen adjustment solenoid -N395- / right headlight screen adjustment solenoid -N396- ) uncovers the screened area of the dipped beam on actuation of the main beam function, thus producing main beam light distribution. This means that with „bi-xenon“ headlights the main beam is al‐ ways automatically adjusted together with the dipped beam. The headlights with gas discharge bulbs and cornering lights do not have an „additional main beam“. The cornering light has the following features:

♦ Swivelling main and dipped beams (dynamic cornering lights): at vehicle speeds in excess of 10 km/h and steering turned.

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For fault finding, use vehicle diagnosis, testing and information system -VAS 5051B- in „Guided fault finding“ mode.

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Automatic headlight range control, cornering lights and onboard supply control unit are equipped with self-diagnosis.

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Fault detection and fault display

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♦ Cornering light bulb (static cornering light): when turning into tight bends (bend radius smaller than 500 m) or when turning a corner at vehicle speeds of less than 50 km/h

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Note

The bulb failure -K170- warning lamp flashes in the dash panel insert if the headlight range control or the variable front lighting has a fault.

4.2

Assembly overview

1 - Cover cap 2 - Cover cap 3 - Front left turn signal bulb M5- / front right turn signal bulb -M7❑ Bulb: PSY 12 V/24 W ❑ Renewing ⇒ page 284 4 - Left side light bulb -M1- / right side light bulb -M3❑ Bulb: wedge-base bulb 12 V/5 W ❑ Renewing ⇒ page 286 5 - Left headlight range control motor -V48- / right headlight range control motor -V49❑ Removing and installing ⇒ page 292 ❑ Checking ⇒ page 292

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7 - Headlight ❑ Removing and installing ⇒ page 280 ❑ Adjusting headlight in‐ stallation position ⇒ page 282 ❑ Repairing headlight se‐ curing tabs ⇒ page 296 ❑ Converting for driving on left/right ⇒ page 294

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8 - Left headlight starter for gas discharge bulb -J426- / right headlight starter for gas discharge bulb -J427❑ Removing and installing ⇒ page 287 9 - Bolt ❑ 1.4 Nm 10 - Guide

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4. Headlights with gas discharge bulbs and cornering lights (from MY2010)

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279

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 12 - Power output module for left headlight -J667- / power output module for right headlight -J66813 - Front end support part 14 - Vehicle level sender ❑ Removing and installing ⇒ page 294 15 - Bolts ❑ 5 Nm 16 - Headlight range control unit -J431❑ 1.5 Nm ❑ Removing and installing ⇒ page 290 ❑ Coding ⇒ page 291

4.3

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Removing and installing headlight

A- .

♦ Illustrations show removal and installation of the left headlight.

Removal and installation of the right headlight are carried out in the same way.

♦ If a headlight is removed, it should always be adjusted follow‐

ing installation ⇒ Maintenance ; Booklet 20.1 ; Description of work .

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-

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♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Remove the radiator grille ⇒ General body repairs, exterior; Rep. gr. 66 . – Remove front bumper cover ⇒ General body repairs, exterior; Rep. gr. 63 .

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Caution

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♦ You do not have to disconnect the earth wire of the battery -

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Note

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Release and disconnect multi-pin connector -1-. – Remove bolt -2- on inner part of headlight.

– Pull headlight forwards and straight out of body aperture. Installing

Carry out installation in the reverse sequence, noting the follow‐ ing:

– Insert headlight with the three guides on underside into mount‐ ings -arrows- on guide and push into body aperture.

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– Unscrew the three bolts -arrows-.

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– First, screw in the three upper bolts -arrows-.

4. Headlights with gas discharge bulbs and cornering lights (from MY2010)

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281

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Then, screw in bolt -2- on rear of headlight. – Tighten all threaded connections to specified torques ⇒ page 279 . – Check headlight functions. – Check headlight installation position is central, i.e. shut lines/ gaps are equal around headlight. If the shut lines/gaps around the headlight are uneven, the instal‐ lation position must be adjusted ⇒ page 282 . Note

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4.4

Adjusting headlight installation position

Installation position is corrected for headlights with gas discharge bulbs and cornering light in same way as for headlights with hal‐ ogen bulbs. Adjusting headlight installation position ⇒ page 217

4.5

Renewing bulbs

4.5.1

Renewing gas discharge bulb WARNING

♦ Within the glass envelope of a gas discharge bulb, pres‐ sure can range from between 7 bar (cold) and 100 bar (hot). Temperatures can reach up to 700 degrees Celsius on the glass bulb. Prote cted by c o py rig h t . Co py i

♦ Always wear safety goggles and gloves when removing and installing gas discharge bulbs!

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♦ Observe safety notes for gas discharge bulbs ⇒ page 258 .

Note

The following diagrams show renewal of left gas discharge bulb -L13- in left headlight. Right gas discharge bulb -L14- in right headlight is renewed in the same way. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

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♦ Should the glass envelope explode, there is a risk of injury from burning.

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– Check headlight adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Removing – Remove headlight ⇒ page 280 . – Pull cover cap -1- off headlight back.

– Unlock connector -1- by pressing button on side -arrow- and pull it off downwards.

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4. Headlights with gas discharge bulbs and cornering lights (from MY2010)

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283

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm te o a itte ir v du p or nl f e ng

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– Turn left gas discharge bulb -L13- -1- in -direction of arrowand carefully pull it backwards out of reflector. Installing

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Caution

♦ Do not touch glass envelope when fitting right gas dis‐ charge (xenon) bulb -L13- . Fingers leave traces of grease on the glass envelope, which evaporate when the left gas discharge (xenon) bulb -L13- is switched on and cause the glass envelope to cloud over. ♦ Ensure glass envelope of left gas discharge (xenon) bulb -L13- is not stressed mechanically. The glass envelope is extremely sensitive and is also under a high internal pres‐ sure.

AG.

Prote cted by

– Check headlight functions. – Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work . If a headlight with automatic range control is removed, the basic setting of the headlights is always to be checked after installation ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

4.5.2

Renewing turn signal bulb

Note ♦ The headlight does not have to be removed to change the

bulb.

♦ The following illustrations show how to change the front right

turn signal bulb -M7- in the right headlight. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

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Carry out installation in the reverse sequence, noting the follow‐ ing:

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♦ When installing cover cap, ensure that it seats properly. The ingress of water will lead to permanent damage to the headlight.

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♦ Avoid looking directly into the collimated beam as the UV radiation from the left gas discharge (xenon) bulb -L13- is about 2.5 times higher than from normal halogen bulbs.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Removing – Release cover cap -2- by turning it anti-clockwise and remove.

– Turn bulb holder -1- in -direction of arrow- and pull it back‐ n AG. Volkswagen AG do es n wage wards out of reflector together with front right turn signal bulb ot g olks V y ua -M7- . db ran e s ri ho ut a ss

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– Press locks -arrows- and pull right front turn signal bulb -M7-1- out of bulb holder -2-. Note

The right front turn signal bulb -M7- is permanently attached to the bulb holder and cannot be dismantled.

AG.

♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over.

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♦ When installing cover cap, ensure that it seats properly. The ingress of water will lead to permanent damage to the headlight.

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Installing

Carry out installation in the reverse sequence, noting the follow‐ ing: – Check headlight functions.

4. Headlights with gas discharge bulbs and cornering lights (from MY2010)

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 olkswagen AG en AG. V

4.5.3

does wag not Renewing olks side light bulb g yV

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♦ The headlight does not have to be removed to change the

bulb.

♦ The following diagrams show renewal of the left side light bulb

-M1- in the left headlight. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

Removing

– Release cover cap -2- by turning it anti-clockwise and remove.

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– Taking connected wiring lengths into consideration, pull bulb holder -1- together with left side light bulb -M1- out of reflector.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull left side light bulb -M1- -1- in -direction of arrow- out of bulb holder -2-. Installing Caution

♦ When installing cover cap, ensure that it seats properly. The ingress of water will lead to permanent damage to the headlight. ♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over. Carry out installation in the reverse sequence, noting the follow‐ ing: – Check headlight functions.

4.6

Headlight starter for gas discharge bulb

The left headlight starter for gas discharge bulb -J426- / right headlight starter for gas discharge bulb -J427- is located on the underside of the respective headlight housing.

4.6.1

Removing and installing headlight start‐ er for gas discharge bulb

Note

Caution

♦ Remove the ignition key.

Removing – Remove headlight ⇒ page 280 .

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♦ Switch off ignition and all electrical consumers.

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4. Headlights with gas discharge bulbs and cornering lights (from MY2010)

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Carry out installation in the reverse sequence, noting the follow‐ ing: Caution

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–

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Ensure seal is seated correctly when installing right headlight starter for gas discharge bulb -J427- . The ingress of water will lead to permanent damage to the headlight. – Tighten all threaded connections to specified torques ⇒ page 279 . – Check headlight functions.

Power output module for headlight

Note

The following illustrations show removing or installation of the power output module for headlight -J668- for the right headlight. For the left headlight, removing or installation is carried out in the same way. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Remove headlight ⇒ page 280 .

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Removing and installing power output module for headlight

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4.7.1

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Power output module for left headlight -J667- / power output mod‐ ule for right headlight -J668- is located on the underside of the respective headlight housing.

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When right power output module for headlight -J668- is pulled off from headlight housing, electrical connectors are simultaneously disconnected. – Pull right power output module for headlight -J668- -1- at right angles out of headlight housing. Installing

Carry out installation in the reverse sequence, noting the follow‐ ing: Caution

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– Tighten all threaded connections to specified torques ⇒ page 279 .

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Note

Control unit for headlight range control -J431- must be recoded if a new power output module for right headlight -J668- is installed ⇒ page 291 . Then subsequently perform the basic setting of headlights ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work . – Check headlight functions.

4.7.2

Checking power output module for headlight

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

The following procedure enables you to test the power output module for left headlight -J667- / power output module for right headlight -J668- . Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- .

4. Headlights with gas discharge bulbs and cornering lights (from MY2010)

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system ♦ 01 - On Board Diagnosis capable systems ♦ Automatic headlight range control_cornering light ♦ Electrical components, automatic headlight range control ♦ Power output module for headlight

4.8

Headlight range control unit -J431-

4.8.1

Removing and installing headlight range control unit -J431Caution

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–

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Press locking lug -arrow- and swing arm -1- in direction of -arrow 2- and pull off connector. Installing Carry out installation in the reverse sequence, noting the follow‐ ing: – Tighten all threaded connections to specified torques ⇒ page 279 . Note

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– Check headlight functions.

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4.8.2

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– Check headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

Coding headlight range control unit J431-

Special tools and workshop equipment required

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The following procedure enables you to code control unit for headlight range control -J431- .

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♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system ♦ 01 - On Board Diagnosis capable systems ♦ Automatic headlight range control, cornering lights ♦ Headlight range control functions ♦ Coding AFS headlight range control unit

4. Headlights with gas discharge bulbs and cornering lights (from MY2010)

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

4.9

Headlight range control motor

4.9.1

Removing and installing headlight range control motor

Headlight range control motor cannot be removed in headlights with gas discharge bulbs and cornering light. The headlight must be renewed if the headlight range control mo‐ tor is defective.

4.9.2

Checking headlight range control motor

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

The following components can be tested: ♦ Headlight range control motor, left -V48♦ Headlight range control motor, right -V49Procedure

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♦ Electrical system

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♦ Body

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– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

♦ 01 - On Board Diagnosis capable systems ♦ Automatic headlight range control, cornering lights ♦ Electrical components, automatic headlight range control ♦ Headlight range control motor

4.10.1

Checking swivel module position sensor

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♦ 01 - On Board Diagnosis capable systems

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The following procedure enables you to test the left swivel module position sensor -G474- / right swivel module position sensor G475- .

♦ Electrical components, automatic headlight range control ♦ Swivel module position sensor

4.11

Headlight screen adjustment solenoid

With conventional xenon headlights, the gas discharge bulbs only generate the dipped beam. The „bi-xenon“ features makes it pos‐ sible to generate both the dipped beam and the main beam with „one“ gas discharge bulb. To achieve this, an electromechanical adjuster ( left headlight screen adjustment solenoid -N395- / right headlight screen adjustment solenoid -N396- ) uncovers the screened area of the dipped beam on actuation of the main beam function, thus producing main beam light distribution.

4.11.1

Removing and installing headlight screen adjustment solenoid

The headlight screen adjustment solenoid on left -N395- / head‐ light screen adjustment solenoid on right -N396- are located inside the respective headlight and can neither be individually re‐ newed nor adjusted. In the event of damage, the headlight must be renewed ⇒ page 280 .

4.11.2

Testing headlight screen adjustment solenoid

The left headlight screen adjustment solenoid -N395- / right head‐ light screen adjustment solenoid -N395- can be checked using the final control diagnosis of the onboard supply control unit J519- . 4. Headlights with gas discharge bulbs and cornering lights (from MY2010)

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4.12

Vehicle level sender

4.12.1

Removing and installing vehicle level sender n AG. Volkswagen A

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LED module for daytime running light and side light

4.13.1

Removing and installing LED module for daytime running light and side light

The left LED module for daytime running light and side light -L176and the right LED module for daytime running light and side light -L177- are located inside the respective headlight and cannot be renewed individually. In the event of damage, the headlight must be renewed ⇒ page 280 .

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Converting headlights for use when driv‐ ing on the left or right

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4.14.1

Note ♦ Before working on gas discharge headlights, always switch off

the headlights and remove the ignition key.

♦ The procedure for converting the headlights is the same for

both sides and is described in the following for the right head‐ light. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Procedure – Remove headlight ⇒ page 280 .

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4.14

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The vehicle level senders are part of the adaptive suspension system. Removal and installation of vehicle level sender ⇒ Run‐ ning gear, axles, steering; Rep. gr. 43 .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove cover cap -1-. WARNING

♦ Within the glass envelope of a gas discharge bulb, pres‐ sure can range from between 7 bar (cold) and 100 bar (hot). Temperatures can reach up to 700 degrees Celsius on the glass bulb. The reflector is therefore hot as well. ♦ There is a risk of injury from burning. ♦ Always allow the headlight to cool for a sufficient period of time. – Turn the regulator -2- in desired direction with an appropriate cross-head screwdriver. Lever -1- moves then into position - A- or -B-. Lever -1- up = driving on left -ALever -1- down = driving on right -BCaution

When installing cover cap, ensure cap is seated correctly. The ingress of water will lead to permanent damage to the head‐ light. – Lock headlight housing with cover cap again. – Install headlight ⇒ page 280 . – Deactivating cornering light ⇒ page 295 . – Check headlight functions. AG. Volkswagen ifGnecessary – Check headlight settings andwadjust do agen headlights A lks ; Descriptions of workes.not ⇒ Maintenance ; Booklety Vo20.1 gu b ed

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Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

If the headlights with gas discharge bulbs and cornering lights are converted to the direction of traffic (driving on the left or right) relevant to the country in which the vehicle is being driven using

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Deactivating cornering light function when converting headlights

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♦ 01 - On Board Diagnosis capable systems ♦ Automatic headlight range control, cornering lights ♦ Headlight range control functions

♦ Conversion between right-hand/left-hand traffic

4.15

Repairing headlight securing tabs

If one or more headlight retaining tabs are damaged or broken off, they can be renewed by installing the repair kit. There is no need to renew the entire headlight.

♦ Check that there is no further damage to the headlight that

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would make installation of the repair kit unnecessary.

♦ Each repair kit includes the outer, the centre and the inner

headlight retaining tab and the associated bolts/screws.

Repair of headlight retaining tabs on headlights with gas dis‐ charge bulbs and cornering light in same way as for headlights with halogen bulbs. Repairing headlight securing tabs ⇒ page 231

4.16

Adjusting headlights

Adjusting headlights with gas discharge bulbs and cornering lights ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

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headlights ⇒ ETKA (electronic parts catalogue) .

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♦ Body

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– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

5

Fog lights

Fault detection and fault display The onboard supply control unit is equipped with self-diagnosis. For fault finding, use vehicle diagnosis, testing and information system -VAS 5051B- in „Guided fault finding“ mode.

5.1

Assembly overview - fog lights (up to MY2009)

1 - Front bumper 2 - Vent hose 3 - Left fog light bulb -L22- / right fog light bulb -L23❑ Bulb: H11 12 V/55 W ❑ Removing and installing ⇒ page 300 4 - Fog light housing ❑ Removing and installing ⇒ page 298 5 - Cover cap 6 - Bolt ❑ 1.5 Nm

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5. Fog lights

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

5.2

Assembly overview - fog lights (from MY2010)

1 - Front bumper cover 2 - Fog light housing ❑ Removing and installing ⇒ page 299 3 - Bolt ❑ 2 Nm 4 - Vent hose 5 - Left fog light bulb -L22- / right fog light bulb -L23- / left cornering light bulb -L148- / right cornering light bulb L149❑ Bulb: HB4 12 V/51 W ❑ Removing and installing ⇒ page 300 6 - Cover cap

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Removing and installing fog lights (up to MY2009)

The illustrations show removal and installation for the left fog light.

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♦ Remove the ignition key. Removing – Remove bolt -2-.

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♦ Switch off ignition and all electrical consumers

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5.3

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– Pull fog light housing out of bumper and disconnect connector -arrow-. Carry out installation in the reverse sequence, noting the follow‐ ing: – Tighten all threaded connections to specified torques ⇒ page 297 . – Check function of headlight.

– Check fog light settings and adjust ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

The illustrations show removal and installation for the left fog light.

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Removing and installing fog lights (from MY2010)

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Caution

♦ Switch off ignition and all electrical consumers ♦ Remove the ignition key.

5. Fog lights

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299

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Removing – Unclip cover cap -1- from retainers.

– Unscrew bolt -arrow-.

–

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– Tighten all threaded connections to specified torques ⇒ page 298 . – Check function of headlight. – Check fog light settings and adjust ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

Removing and installing fog light/corner‐ ing light bulb Note

– Remove fog light ⇒ page 298 . AG.

300

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Removing

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The illustration shows removal and installation on left fog light.

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5.5

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Carry out installation in the reverse sequence, noting the follow‐ ing:

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Turn bulb holder with bulb -1- in direction of -arrow- and re‐ move from fog light. The bulb is permanently attached to the bulb holder and cannot be renewed separately. Installing Carry out installation in the reverse sequence, noting the follow‐ ing: – Check function of headlight. . Volkswagen AG – Check fog light settings and adjust ⇒ Maintenancew;aBooklet gen AG does ks not l o 20.1 ; Descriptions of work . gu yV

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Adjusting fog lights

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301

Bulb for turn signal repeater light and entry light in exterior mirror

General description

The driver side turn signal repeater bulb in exterior mirror -L131- / passenger side turn signal repeater bulb in exterior mirror -L132(side-mounted turn signals) are integrated in the exterior mirror housings. In addition, there is one driver side entry light in exterior mirror W52- / front passenger side entry light in exterior mirror -W53- in each of the exterior mirror housings, which illuminate the entry area around the open driver and front passenger door in the dark. 1 - Driver side turn signal repeater bulb in exterior mirror -L131- / passenger side turn signal repeater bulb in exterior mirror -L1322 - Driver side entry light in exterior mirror -W52- / front passenger side entry light in exterior mirror -W53Fault detection and fault display

Removing and installing turn signal bulb

The driver side turn signal repeater bulb in exterior mirror -L131- / passenger side turn signal repeater bulb -L132- are installed in the left/right exterior mirror housing respectively. In the event of damage, the complete driver side turn signal lamp in exterior mirror -L131- / passenger side turn signal lamp in ex‐ terior mirror -L132- must be renewed. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Remove driver side turn signal repeater bulb in exterior mirror -L131- / passenger side turn signal repeater bulb in exterior mirror -L132- ⇒ General body repairs, exterior; Rep. gr. 66 Installing – Install driver side turn signal repeater bulb in exterior mirror L131- / passenger side turn signal repeater bulb in exterior mirror -L132- ⇒ General body repairs, exterior; Rep. gr. 66

6.2

Removing and installing entry light in ex‐ terior mirror

The driver side entry light in exterior mirror -W52- / front passen‐ ger side entry light in exterior mirror -W53- are installed in the left and right exterior mirror housing respectively. There is no need to remove exterior mirror to remove and install driver side entry light in exterior mirror -W52- / front passenger side entry light in exterior mirror -W53- . The procedure for removal and installation of the driver side entry light in exterior mirror -W52- and front passenger side entry light

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6.1

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For fault finding, use vehicle diagnosis, testing and information system -VAS 5051B- in „Guided fault finding“ mode.

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6

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 in exterior mirror -W53- is the same and is therefore described for one side only. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing

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– Fold exterior mirror

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– Remove bolt -1-.

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– Unclip driver side entry light in exterior mirror -W52- from ex‐ terior mirror in -direction of arrow- and pull it out as far as the wiring allows. AG.

6. Bulb for turn signal repeater light and entry light in exterior mirror

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303

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 olkswagen-1. Vhousing AG dof n AGof – Pull bulb holder -2- in -direction of arrowageout oes ksw-W52- . not l o driver side entry light in exterior mirror gu yV b

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– Pull push-fit bulb -1- in -direction of arrow- out of bulb holder -2-. Push-fit bulb: 12 V/6 W Installing

Carry out installation in the reverse sequence, noting the follow‐ ing: – Following installation, check operation of exterior mirrors.

AG.

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Renewing bulb:

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

The front left side marker bulb -M33- / front right side marker bulb -M34- are renewed in exactly the same way. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 . – Release side marker light -1- by pushing locking lug in -direction of arrow-. – Pull bulb holder -2- out of side marker light. Renewing front left side marker bulb -M33- / front right side mark‐ er bulb -M34- :

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Installing

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– Pull front left side marker bulb -M33- -1- in direction of arrow out of bulb holder -2-.

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Removing

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Removing and installing front side marker light in front bumper

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7

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Carry out installation in the reverse sequence, noting the follow‐ ing: AG.

– Following installation, carry out functional check.

7. Removing and installing front side marker light in front bumper

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305

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

8

Rear side marker bulb (USA/Canada only)

The function of the rear side marker light -M12- is taken over by the left tail light bulb -M4- / right tail light bulb -M2- .

AG.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

Tail lights

9.1

Assembly overview - tail light in side panel (bulbs) - saloon es, in part or in w l purpos hole ercia , is n m ot com

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9.2

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5 - Bulb carrier ❑ Removing and installing ⇒ page 308

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4 - Rear left turn signal bulb M6- / rear right turn signal bulb -M8-

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3 - Tail light housing in side panel ❑ Contains LED module for daytime running light and side light ❑ Removing and installing ⇒ page 307

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2 - Left brake light bulb -M9- / right brake light bulb -M10-

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Removing and installing tail light in side panel (bulbs) - saloon Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Push side panel trim to the side.

9. Tail lights

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307

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull off connector -1-. – Unscrew securing nuts -2- from tail light in lower part of side panel. – Remove tail light. Installing

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Tail light connector in side panel must be „heard“ to engage when reconnecting. – When installation is complete, check gap/shut lines of tail light to body.

9.3

Removing and installing tail light bulb carrier in side panel - saloon

Removing

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– Unclip fastening tabs -1- -in direction of arrow- and unhook bulb carrier from tail light housing -2-. Installing Installation is carried out in reverse order of removal.

308

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– Pull off connector -1-.

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ho – Tighten all threaded connections to specified torques ut a ⇒ page 307ss.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

9.4

Tail light in side panel (LED) - saloon

1 - Nut ❑ 3.5 Nm 2 - Tail light in side panel ❑ Removing and installing ⇒ page 309

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Removing and installing tail light in side panel (LED) - saloon agen lksw Vo by

9.5

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The tail light in the side panel with LED cannot be dismantled further. It comprises the following components: AG.

♦ Left tail light bulb -M4- / right tail light bulb -M2♦ Left brake and tail light bulb -M21- / right brake and tail light bulb -M22♦ Rear left turn signal bulb -M6- / rear right turn signal bulb -M8Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Push side panel trim to the side. 9. Tail lights

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309

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull off connector -1-. – Unscrew nuts -2- from tail light in lower part of side panel. – Remove tail light. Installing Carry out installation in the reverse sequence, noting the follow‐ ing: – Tighten all threaded connections to specified torques ⇒ page 309 . Note ♦ Tail light connector in side panel must be „heard“ to engage

when reconnecting.

♦ Connector is locked correctly when locking tab is pressed

down again!

– When installation is complete, check gap/shut lines of tail light to body.

9.6

Assembly overview - tail light in rear lid - saloon

1 - Nut ❑ 3.5 Nm 2 - Bulb carrier ❑ Removing and installing ⇒ page 311

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310

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

9.7

Removing and installing tail light in rear lid - saloon Caution

♦ Switch off ignition and all

– Unclip service cover from trim in rear lid. – Pull off connector -2-.

– Unscrew nuts -1- from tail light in rear lid. – Remove tail light. Installing

Carry out installation in the reverse sequence, noting the follow‐ ing:

AG.

– Tighten all threaded connections to specified torques ⇒ page 310 .

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– Place washers -2- on raised section (dome) -1-.

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– Fix washer -2- before fitting to raised section (dome) -1- using a drop of adhesive (Loctite) to prevent it from falling into the cavity of the vehicle body.

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Removing

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♦ Remove the ignition key.

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– When installation is complete, check gap/shut lines of tail light to body.

9.8

Removing and installing tail light bulb holder in rear lid - saloon Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Unclip service cover from trim in rear lid.

9. Tail lights

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311

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull off connector -2-. Note

The lower trim of the rear lid need not be removed. For illustration purposes, the lower trim of the rear lid is not shown in the following picture.

– Release both lugs -in direction of arrow- and take out bulb carrier -1-. Installing Installation is carried out in reverse order of removal.

AG.

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Rep. gr.94 - Lights, bulbs, switches - exterior

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

Assembly overview - tail light - Variant

7 - Bulb carrier ❑ Removing and installing ⇒ page 314

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9.10

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6 - Rear left turn signal bulb M6- / rear right turn signal bulb -M8-

AG.

5 - Rear fog light bulb -L20- / right reversing light bulb -M17-

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4 - Tail light housing ❑ Removing and installing ⇒ page 313

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3 - Right tail light bulb -M2- / left tail light bulb -M4-

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2 - Left brake light bulb -M9- / right brake light bulb -M10-

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1 - Nut ❑ 3.5 Nm

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9.9

Removing and installing tail light - Var‐ iant Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Push side panel trim/cover to the side.

9. Tail lights

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313

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Disconnect connector -3-. – Unscrew nuts -2- and -4- for tail light -1-. – Remove tail light -1-. Installing Carry out installation in the reverse sequence, noting the follow‐ ing: – Tighten all threaded connections to specified torques ⇒ page 313 . Note

Tail light connector in side panel should engage „audibly“. – When installation is complete, check gap/shut lines of tail light to body.

9.11

Removing and installing tail light bulb holder - Variant Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Push side panel trim/cover to the side. AG. Volkswagen AG d agen oes ksw not l o V gu by ara d nte ir se o eo h t u ra a c ss

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– Disconnect connector -2-.

– Unclip fastening tabs -in direction of arrow- and unhook bulb carrier -1- from tail light housing -3-. Installing

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Rep. gr.94 - Lights, bulbs, switches - exterior

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314

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Installation is carried out in reverse order of removal.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

Removing

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Removing and installing number plate lights

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– Remove screws -arrows- from left number plate light -X4- . – Remove lens with left number plate light -X4- . Bulb: festoon C 12 V/5 W Installing Installation is carried out in reverse order of removal.

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10. Removing and installing number plate lights

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315

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

11

Additional brake lights

11.1

Removing and installing additional brake light bulb -M25- - saloon Note

♦ Failure of LEDs in additional brake lights: ♦ The individual LEDs in the additional brake lights are com‐

prised in groups of four LEDs and are supplied with current in groups.

♦ The additional brake light is designed in such a way that the

legal requirements are still met in the event that one LED group fails.

♦ If a further LED group fails, these requirements are no longer

met according to the legislator.

♦ Due to the failure of one LED group, the intact LEDs are placed

under increased strain; it must be anticipated that further LED groups will soon fail.

♦ If more than four individual LEDs in the additional brake light

have failed, the additional brake light must be renewed (repair measure). Caution

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♦ Switch off ignition and all

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♦ Remove the ignition key.

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Removing

– Remove strip roof leading edge ⇒ General body repairs, in‐ terior; Rep. gr. 70 . – Disconnect connector -1-.

– Push high-level brake light bulb -M25- -in direction of arrowto rear window. Installing

Carry out installation in the reverse sequence, noting the follow‐ ing: – When installing additional brake light bulb -M25- , ensure the seal is seated correctly.

The additional brake light bulb -M25- cannot be dismantled.

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AG.

The illumination of high-level brake light bulb -M25- is provided by LEDs.

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The additional brake light bulb -M25- is located in the roof spoiler over the rear window.

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Removing and installing additional brake light bulb -M25- - estate

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11.2

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 In the event of damage, the complete additional brake light bulb -M25- must be renewed. Special tools and workshop equipment required ♦ Removal wedge -T10039/1-

♦

♦ Ensure the seal is not damaged when removing the addi‐ tional brake light bulb -M25- .

Removing

– Insert removal wedge -T10039/1- between upper edge of high-level brake light bulb -M25- and roof spoiler. – Press additional brake light bulb -M25- downwards using re‐ moval wedge -T10039/1- and unclip upper retaining lugs of additional brake light bulb -M25- towards rear. – Then pull the additional brake light bulb -M25- to rear out of opening in the roof spoiler, as far as the connected wiring al‐ lows.

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♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -T10039/1- , removal wedge -VAS 3409- , screwdriver) are used to lever out those components us‐ ing commercially available masking tape.

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♦ Remove the ignition key.

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11. Additional brake lights

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317

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Release and disconnect connector -1- and remove additional AG. Volkswagen AG d agen oes brake light bulb -M25- -2-. ksw not Vol Installing

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Note

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Carry out installation in the reverse sequence, ing:

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Ensure when installing the additional brake light bulb -M25- that the seal is seated correctly. The seal must not form loops or be damaged. – Clip the additional brake light bulb -M25- back into the roof spoiler starting at the lower edge.

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Rep. gr.94 - Lights, bulbs, switches - exterior

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12

Steering column switch Caution

When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 .

Note . Volkswagen AG gen AG does not gu ara nte eo coding ra c

a ♦ When a new steering column electronics control unit is lksw Vo-J527-

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The steering column electronics control unit -J527- is equipped with self-diagnosis.

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For fault finding, use vehicle diagnosis, testing and information system -VAS 5051B- in „Guided fault finding“ mode.

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12. Steering column switch

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

12.1

Assembly overview - steering column switch

1 - Turn signal switch ❑ Consists of turn signal switch -E2- / headlight dipper/flasher switch E4- / cruise control switch -E45❑ The illustration shows the „turn signal switch“ with no cruise control system switch -E45❑ Removing and installing ⇒ page 324 2 - Steering column switch base ❑ Removing and installing ⇒ page 326

6 - Airbag coil connector and return ring with slip ring -F138❑ Removing and installing ⇒ page 322

rrectness of i t to the co nform spec a t ion h re wit in t his

5 - Steering column electronics control unit -J527❑ Removing and installing ⇒ page 321 ❑ Coding ⇒ page 327 ❑ Final control diagnosis ⇒ page 328 .

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4 - Bolt ❑ 1 Nm

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3 - Windscreen wiper switch E❑ Removing and installing ⇒ page 324

7 - Steering angle sender -G85❑ Removing and installing ⇒ page 323 ❑ Basic setting ⇒ page 328

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Rep. gr.94 - Lights, bulbs, switches - exterior

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AG.

When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 .

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Caution

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Removing and installing steering col‐ umn switch

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12.2

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Note

When removing steering column switch, make sure that no chips get into steering column switch while drilling open the shear-head bolts. Removing For removal of the complete steering column switch with the base, the switch is dismantled and the steering lock housing is also re‐ moved. For assembly of the steering lock housing, new shear bolts are required. Even if just one component of the steering col‐ umn switch is removed or renewed, the sequence described as n AG. Volkswagen AG do es n wage follows must be adhered to. o olks

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– Disconnect battery -A- ⇒ page 4 . urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e ng

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– Remove steering wheel ⇒ General body repairs, interior; Rep. ss gr. 69 . – Remove steering column trim ⇒ General body repairs, interior; Rep. gr. 68 .

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Remove components of steering column switch in the following sequence: ♦ Steering column electronics control unit -J527- ⇒ page 321 ♦ Airbag coil connector and return ring with slip ring -F138⇒ page 322 ♦ Steering angle sender -G85- ⇒ page 323 ♦ Turn signal switch -E2- ⇒ page 324

♦ Windscreen wiper switch -E- ⇒ page 324

♦ Steering column switch base ⇒ page 326 Installing

Installation is carried out in reverse order of removal.

AG.

In the event of faults in the steering column switch, the coding of the steering column electronics control unit -J527- must be checked ⇒ page 327 .

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If a new steering column electronics control unit -J527- is instal‐ led, it must be coded ⇒ page 327 .

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Removing and installing steering col‐ umn electronics control unit -J527-

12. Steering column switch

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12.2.1

321

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Removing – Remove bolt -1-. Caution

DO NOT attempt to remove steering. Vcolumn electronics control olkswage AG gen AG securingnclip, doas unit -J527- without releasing es ndescribed wamiddle s k l o o in next step. Failure bto y V do so would damage steeringt gcolumn ua ran ed electronics control te ris unit -J527- . tho au s s

– Insert a piece of wire or a 2.5 mm ∅ drill bit -2- approx. 45 mm into hole -arrow 1- in steering column electronics control unit -J527- to release locking tab -arrow 2-.

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– Using a screwdriver, press against the rear retaining clip -arrow- of the control unit for steering column electronics J527- . – Carefully pull the steering column electronics control unit J527- downwards off the steering column switch.

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– Unclip -arrow A- connector -1- and disconnect from steering column electronics control unit -J527- . AG.

– Pull locking bar -3- out of connector. – Unclip -arrow B- connector -2- and disconnect from steering column electronics control unit -J527- . Installing Carry out installation in the reverse sequence, noting the follow‐ ing: Ensure when fitting the connector that none of the pins become bent and that the connector can be heard to engage.

12.2.2

Removing and installing airbag coil con‐ nector and return ring with slip ring F138WARNING

Airbag coil connector and return ring with slip ring -F138should not be moved out of central position during removal and road wheels should be in „straight-ahead“ position.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Removing – Slightly lift the tabs -arrows- on airbag coil connector and re‐ turn ring with slip ring -F138- -1- and pull airbag coil connector and return ring with slip ring -F138- backwards off steering column. Installing Carry out installation in the reverse sequence, noting the follow‐ ing: When installing airbag coil connector and return ring with slip ring n AG. Volkswagen AG do -F138- , make sure airbag coil connector and lreturn es n wage ring with slip s k ot g Vo ring -F138- is in central position and wheels ua by are in „straightd ran ahead“ position. ir se te o

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♦ The coloured strip (black rectangles) -arrow- must be located in sight window -1-. ♦ The coloured strip (yellow) -arrow- must be in sight window -1-.

AG.

12.2.3

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If a new steering angle sender -G85- in installed, this procedure must be followed by a „basic setting“ ⇒ page 328 .

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Note

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a Central position of airbag coil connector and return ring with slip ss ring -F138- depends on manufacturer and is shown below:

Removing and installing steering angle sender -G85-

Removing – Pull the steering angle sender -G85- -1- backwards and away from the steering column switch -arrow-. Installing Installation is carried out in reverse order of removal.

12. Steering column switch

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323

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

12.2.4

Removing and installing turn signal switch

The „turn signal switch“ comprises the following components: turn signal switch -E2- , headlight dip/flasher switch -E4- and cruise control system switch -E45Note

– Release retaining clips -arrows- using 1.0 mm feeler gauge -1- and take „turn signal switch“ off backwards. Installing

Carry out installation in the reverse sequence, noting the follow‐ ing: The „turn signal switch“ should be heard to engage.

AG.

Removing Note

For reasons of clarity, the steering column switch is shown in the removed state.

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Removing and installing windscreen wiper switch -E-

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12.2.5

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es, in part or in w l purpos hole ercia , is n m m ot p r co erm o e t a itte v i r du p or nl f e g n

Removing

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n AG. Volkswagen AG do es n wage ot g olks V y ua b d ran For reasons of clarity, the steering column ise switch is shown with tee r CCS switch -E45- in the illustration.utho or ac a ss

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Release retaining clips -arrows- using 1.0 mm feeler gauge -1- and take windscreen wiper switch -E- off backwards. Installing Carry out installation in the reverse sequence, noting the follow‐ ing: The windscreen wiper switch -E- should be heard to engage.

rrectness of i t to the co nform spec a t ion h re wit in t his

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t a itte riv du p r o nl f e ng

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12. Steering column switch

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325

Removing and installing steering col‐ umn switch base

Note

To remove the steering column switch base -2-, the shear bolts of the steering lock housing must be drilled out. To reinstall, new shear-head bolts -1- are required ⇒ Parts catalogue (ETKA) . Caution

♦ Ensure that the components mounted on the carrier have been removed before drilling out the shear-head bolts. ♦ The drilling operation can cause swarf to penetrate the adjacent components resulting in damage and/or mal‐ function! Prote cted by c o py rig ht . C op yi

♦ When battery -A- is disconnected and reconnected, the procedure described in the workshop manual must be strictly observed ⇒ page 4 .

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Removing – Disconnect battery -A- ⇒ page 4 . Remove the following components in sequence: – Remove steering wheel ⇒ General body repairs, interior; Rep. gr. 69 . – Remove steering column trim ⇒ General body repairs, interior; Rep. gr. 68 . – Remove steering column electronics control unit -J527⇒ page 321 . – Remove airbag coil connector and return ring with slip ring F138- ⇒ page 322 . – Remove steering angle sender -G85- ⇒ page 323 . – Remove turn signal light switch -E2- ⇒ page 324 . – Remove windscreen wiper switch -E- ⇒ page 324 .

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♦ Keep to the specified sequence when removing compo‐ nents.

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12.2.6

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Separate connector -arrow- on reader coil -3-. The base can be removed once all the components mounted to it have been removed: – Drill out bolts -1- of steering lock housing -3-. Note

Bolts M8 -1-, core diameter 6.8 mm – Pull steering lock housing and steering column switch base -2- backwards off steering column. – Take steering lock housing off steering column switch base. Installing Carry out installation in the reverse sequence, noting the follow‐ ing: – Place the steering lock housing into the steering column switch base. – Push steering column switch base -2- as far as possible onto steering column. – Fit connector -arrow- on reader coil -3-.

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olks – Secure steering lock housing using y V new shear bolts -1- to db steering column. e is

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12.3

es, in part or in w l purpos hole ercia , is n m ot com

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– Tighten shear bolts -1- suntil bolt au

Steering column electronics control unit -J527-

Removing and installing steering column electronics control unit -J527- ⇒ page 321 .

12.3.1

Coding steering column electronics con‐ trol unit -J527-

Special tools and workshop equipment required

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♦ Vehicle diagnosis, testing and information system -VAS 5051B-

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12. Steering column switch

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327

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

♦ Electrical system

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♦

♦ 01 - On Board Diagnosis capable systems ♦ Steering wheel electronics

♦ Steering wheel electronics functions

♦ Coding steering wheel electronics control unit

12.3.2

Final control diagnosis steering column electronics control unit -J527-

Special tools and workshop equipment required

♦ Vehicle diagnosis, testing and information system -VAS 5051B-

– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system ♦ 01 - On Board Diagnosis capable systems ♦ Steering wheel electronics ♦ Steering wheel electronics functions ♦ Steering wheel electronics final control diagnosis

12.4

Steering angle sender -G85-

Removing and installing steering angle sender -G85⇒ page 323 .

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AG.

– In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

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– Connect vehicle diagnosis, testing and information system VAS 5051B- .

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Procedure

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–

n AG. Volkswagen AG do es n wage ot g olks V Using GoTo button, select „Functions/component“ and the y fol‐ ua b d ran ise lowing menu options in succession: tee r o h t or u ac a Body ss

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

12.4.1

Basic setting of steering angle sender G85-

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Running gear n AG. Volkswagen AG do es n wage ot g olks V ua by d ran 01 - On Board Diagnosis capable systems ir se Mark 60 / Mark 70 tee o h t or ac au Anti-lock brake system ABS/EDL/TCS/ESP Mark 60 s s

♦ Brake system

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♦ Functions

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♦ Basic setting of steering angle sender -G85-

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12. Steering column switch

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329

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

13

Ignition/starter switch and lock cylin‐ der Removing and installing steering lock housing pe rm itte d

Caution

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13.1

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When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 . The steering lock could be destroyed. If the steering lock is actuated without lock cylinder, it will block and must be renewed. The steering lock must not be actuated without lock cylinder.

Note

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– Remove steering column switch base ⇒ page 326 .

Removing and installing lock cylinder

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Caution

♦ When battery -A- is disconnected and reconnected, the procedure described in the workshop manual must be strictly observed ⇒ page 4 . ♦ The steering lock could be destroyed. ♦ If the steering lock is actuated without lock cylinder, it will block and must be renewed. ♦ The steering lock must not be actuated without lock cylin‐ der. Removing – Disconnect battery -A- ⇒ page 4 . – Remove steering wheel ⇒ General body repairs, interior; Rep. gr. 69 . – Remove steering column trim ⇒ General body repairs, interior; Rep. gr. 68 . – Remove steering column electronics control unit -J527⇒ page 321 . – Remove airbag coil connector and return ring with slip ring F138- ⇒ page 322 . – Remove steering angle sender -G85- ⇒ page 323 .

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AG.

13.2

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– Disconnect battery -A- ⇒ page 4 .

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Removing

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If the steering lock is to be removed, the steering column switch base must first be removed.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Note ♦ There is no need to remove the switches in order to remove

the lock cylinder.

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k not to the lock cylinder ♦ The immobiliser reader coil -D2- is secured Vol gu by ed and cannot be changed individually. ris

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– Insert ignition key in lock cylinder and turn to position „Drive“.

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Positions for key in lock cylinder: 1-

Position „Stop“

2-

Position „Drive“

3-

Position „Start“

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c s – sPull connector -arrow- off immobiliser reader coil -D2.

For reasons of clarity, the lock cylinder is shown in the following illustration without ignition key. – Insert steel wire (∅ 1.2 mm) into hole -arrow- adjacent to ig‐ nition key. – Using steel wire -2- release -arrow- locking lever -3- of lock cylinder -1-. – Pull lock cylinder -1- out of steering lock housing.

13. Ignition/starter switch and lock cylinder

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331

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Installing Note

For reasons of clarity, the ignition key is not shown in the following illustration. – Insert ignition key in lock cylinder -1- and turn to position „Drive“. – Using steel wire -2- release -arrow- locking lever -3- of lock cylinder -1-. – Place lock cylinder -1- in steering lock housing. Note

The connection for the immobiliser reader coil -D2- must be in‐ serted in the guide on the steering lock housing. – Pull steel wire -2- out of lock cylinder -1- and check lock cyl‐ inder is seated correctly in the steering lock housing. – Fit connector to immobiliser reader coil -D2- . Further installation is performed in reverse sequence.

Removing and installing ignition/starter switch -Durposes, in part or in wh ole, cial p is n mer m ot p o c r erm te o a itte ir v du p or nl f e ng

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Caution

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13.3

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When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 . Removing – Disconnect battery -A- ⇒ page 4 .

– Detach connector -2- from ignition/starter switch -D- -1-. – Release ignition/starter switch -D- using small screwdriver -arrows-.

– Insert ignition/starter switch -D- in steering lock housing until it can be heard to engage.

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AG.

Rep. gr.94 - Lights, bulbs, switches - exterior

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332

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Installing

do c um en

– Pull ignition/starter switch -D- -1- out of steering lock housing.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Insert ignition key in lock cylinder and turn to position „Drive“. Note

The key must be in the „Drive“ position. Positions for key in lock cylinder: 1-

Position „Stop“

2-

Position „Drive“

3-

Position „Start“

– Install all parts in reverse order of removal.

Removing and installing ignition key withdrawal lock solenoid -N376urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t a itte iv du pr r o nl f e ng

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13.3.1

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Note

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The ignition key withdrawal lock solenoid -N376- is located very close to the ignition starter key.

To remove ignition key on vehicles with an automatic gearbox, always move selector lever to position „P“ first then switch off ig‐ nition. Otherwise the ignition key withdrawal lock solenoid -N376will inhibit the removal of the ignition key. Removing

– Remove steering column electronics control unit -J527⇒ page 321 . – Release fastener -2- using a suitable screwdriver.

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Installing

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– The electrical connection will be disconnected automatically.

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– Pull ignition key withdrawal lock solenoid -N376- -1- in direc‐ tion of arrow and out of its mounting.

– Carry out installation in the reverse sequence, noting the fol‐ lowing: AG.

Note

After reconnecting the battery -A- , carry out final control diagno‐ sis to activate ignition key withdrawal lock solenoid -N376⇒ page 328 .

13. Ignition/starter switch and lock cylinder

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333

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

14

Parking aid

14.1

General description

When dealing with complaints, it is absolutely necessary to un‐ derstand the functions and the operation of the parking aid ⇒ Operating instructions . The parking aid system supports the driver during parking ma‐ noeuvres by indicating the distance from the rear of the vehicle to the obstacle by way of acoustic signals. A 4-channel and a 8-channel parking aid system are available. The 4-channel parking aid system consists of: ♦ Parking aid control unit -J446♦ Rear parking aid warning buzzer -H15♦ Rear left centre parking aid sender -G204♦ Parking aid sender, rear left, inner -G334-

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♦ Parking aid sender, rear right, inner -G335-y Volks b ed

is ♦ Rear right centre parking aid sender h-G205or

♦ It is possible that the first software version of the parking aid

control unit -J446- may display various sender designations due to the various levels of software. In this case allocation is as follows:

♦ Rear centre left parking aid sender -G204- is rear left parking

aid sender -G203-

♦ Rear left inner parking aid sender -G334- is rear centre left

parking aid sender -G204-

♦ Rear right inner parking aid sender -G335- is rear centre right

parking aid sender -G205-

♦ Rear centre right parking aid sender -G205- is rear right park‐

ing aid sender -G206-

The 8-channel parking aid system consists of: ♦ Parking aid control unit -J446-

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♦ Front centre left parking aid sender -G254-

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♦ Rear left parking aid sender -G203♦ Rear centre left parking aid sender -G204♦ Rear centre right parking aid sender -G205♦ Rear right parking aid sender -G206♦ Front parking aid warning buzzer -H22♦ Rear parking aid warning buzzer -H15♦ Parking aid button -E266-

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AG.

♦ Front right parking aid sender -G252-

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♦ Front centre right parking aid sender -G253-

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♦ Front left parking aid sender -G255-

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Functioning To switch on, press, with ignition on, parking aid button -E266- or engage reverse gear. To switch off, press parking aid button E266- again ( parking aid warning lamp -K136- goes out) or drive forwards with a speed over about 15 km/h. A brief audible signal is given and the parking aid warning lamp K136- lights up when the parking aid system is ready. If a fault is detected, a continuous audible signal is given for 5 seconds and the parking aid warning lamp flashes -K136- . The intervals between the warning signals become proportionally shorter as the distance decreases. At distances of less than 30 lkswa en AG AG. Vointo cm the warning signals merge agcontinuous does tone. Special sit‐ agen nosignal. lksw uation: reversingVoparallel to a wall: no warning tg by ed

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The parking aid system is equipped with self-diagnosis. ss

For fault finding, use vehicle diagnosis, testing and information system -VAS 5051B- in „Guided fault finding“ mode.

14.2

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To check parking aid system as a whole, perform final control diagnosis ⇒ page 354 .

Assembly overview - 4-channel parking aid

1 - Rear parking aid warning buzzer -H15❑ Saloon: under rear shelf ❑ Variant: behind right side luggage compart‐ ment trim ❑ Saloon: removing and installing ⇒ page 351 ❑ Variant: removing and installing ⇒ page 351 ht rig py Co t.

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2 - Parking aid control unit J446❑ Behind right side lug‐ gage compartment trim ❑ Saloon: removing and installing ⇒ page 338 ❑ Variant: removing and installing ⇒ page 338 ❑ Coding ⇒ page 341 ❑ Adjusting optical display ⇒ page 341 Prote cted by

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3 - Rear right centre parking aid sender -G205❑ In rear bumper cover ❑ Removing and installing ⇒ page 342 ❑ Renew sender and sender holder in the event of repair ⇒ page 347 . 4 - Parking aid sender, rear right, inner -G335❑ In rear bumper cover

14. Parking aid

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335

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Volkswa

gen AG AG. ❑ Removing and installing does agen ksw not l o V ⇒ page 342 gu y b ara ed s i r holder in the event of repair ⇒ page 347nte.e ❑ Renew sender and sender o h

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Note

♦ It is possible that the first software version of the parking aid

control unit -J446- may display various sender designations due to the various levels of software. In this case allocation is as follows:

♦ Rear centre left parking aid sender -G204- is rear left parking Prote cted by c o py rig ht. C op yi

♦ Rear left inner parking aid sender -G334- is rear centre left agen lksw Vo by

parking aid sender -G204-

♦ Rear right inner parking aid sender -G335- is rear centre right AG.

parking aid sender -G205-

♦ Rear centre right parking aid sender -G205- is rear right park‐

ing aid sender -G206-

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aid sender -G203-

rrectness of i t to the co nform spec a t i h re o n in wit thi s

6 - Rear left centre parking aid sender -G204❑ In rear bumper cover ❑ Removing and installing ⇒ page 342 ❑ Renew sender and sender holder in the event of repair ⇒ page 347 .

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5 - Parking aid sender, rear ss left, inner -G334❑ In rear bumper cover ❑ Removing and installing ⇒ page 342 ❑ Renew sender and sender holder in the event of repair ⇒ page 347 .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

14.3

Assembly overview - 8-channel parking aid

1 - Parking aid senders in rear bumper cover ❑ Rear left parking aid sender -G203❑ Rear centre left parking aid sender -G204❑ Rear centre right park‐ ing aid sender -G205❑ Rear right parking aid sender -G206❑ Removing and installing ⇒ page 342 ❑ Checking ⇒ page 350 ❑ Renewing ⇒ page 349 ❑ Renew sender and sender holder in the event of repair ⇒ page 347 .

3 - Parking aid button -E266❑ In centre console next to gear lever ❑ Removing and installing ⇒ page 418 ❑ Checking ⇒ page 355 4 - Parking aid control unit -J446❑ Above relay carrier in driver's footwell ❑ Removing and installing (left-hand drive vehicle) ⇒ page 339 ❑ Removing and installing (right-hand drive vehicle) ⇒ page 340 ❑ Coding ⇒ page 341 ❑ Adjusting optical display ⇒ page 341 ❑ Final control diagnosis ⇒ page 354 .

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5 - Front parking aid warning buzzer -H22❑ Removing and installing ⇒ page 353 ❑ Adjusting volume ⇒ page 353 ❑ Adjusting pitch ⇒ page 354

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2 - Rear parking aid warning n AG. Volkswagen AG do buzzer -H15es n wage ot g olks V ua ❑ Saloon: removing and d by ran ir se installing ⇒ page 351 tee o h t or ac auand ❑ Variant: removing s s installing ⇒ page 351 ❑ Adjusting volume ⇒ page 352 ❑ Adjusting pitch ⇒ page 352

6 - Sender for parking aid in front bumper cover ❑ Front left parking aid sender -G255❑ Front centre left parking aid sender -G254❑ Front centre right parking aid sender -G253❑ Front right parking aid sender -G252❑ Removing and installing ⇒ page 345 14. Parking aid

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337

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ❑ Checking ⇒ page 350 ❑ Renewing ⇒ page 349 n AG. Volkswagen AG do es n wage ot g olksrepair ⇒ page 347 . ❑ Renew sender and sender holder in the event of V y u ss

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Removing and installing parking aid control unit -J446- (4-channel) - saloon urposes, in part or in wh ole, cial p is n mer m ot p r co erm o te a itte ir v du p or nl f e ng

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The parking aid control unit -J446- is located behind the right lug‐ gage compartment side trim panel. Caution

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14.4

b ed ris o th au

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing

– Remove right luggage compartment side trim panel ⇒ General body repairs, interior; Rep. gr. 70 . – Remove connector -2- on parking aid control unit -J446- -1-.

Removing and installing parking aid control unit -J446- (4-channel) - estate

The parking aid control unit -J446- is located behind the right lug‐ gage compartment side trim panel. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

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AG.

14.5

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Installation is carried out in reverse order of removal.

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Installing

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– Press locking lugs -arrows- of bracket outwards and remove parking aid control unit -J446- -1- from bracket.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Removing – Remove right luggage compartment side trim panel ⇒ General body repairs, interior; Rep. gr. 70 . – Remove connector -2- on parking aid control unit -J446- -1-. – Press locking lugs -arrows- of bracket -3- outwards and re‐ move parking aid control unit -J446- -1- from bracket -3-. Installing Installation is carried out in reverse order of removal.

14.6

Removing and installing parking aid . Volkswagen AG control unit -J446n AG(8-channel) doe wage s no t

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Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing

– Remove trim in driver's footwell ⇒ General body repairs, in‐ terior; Rep. gr. 68 . – Remove securing screw -arrow- for parking aid control unit J446- above relay carrier. ht rig py Co t.

– Remove windscreen wiper system ⇒ page 183 .

rrectness of i t to the co nform spec a t i h re o n in wit thi s

The parking aid control unit -J446- is located in the driver's foot‐ well, above the relay carrier.

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urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e ng

ss Removing and installing parking aid control unit -J446- (left-hand drive vehi‐ cle)

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14.6.1

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14. Parking aid

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339

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove the three nuts -arrows- and remove cover -1-.

olkswagen AG en AG. V

does ag – Detach the three connectors -arrowsksw and remove the parking not Vol gu y b aid control unit -J446- -1- upwards out of bracket. ara d e

– Tighten bolt of parking aid control unit -J446- to 1.5 Nm.

14.6.2

Removing and installing parking aid control unit -J446- (right-hand drive ve‐ hicle)

The parking aid control unit -J446- is located in the driver's foot‐ well, above the relay carrier. Caution

♦ Switch off ignition and all electrical consumers.

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AG.

Prote cted by c o py rig ht . C op yi

Removing

– Remove trim in driver's footwell ⇒ General body repairs, in‐ terior; Rep. gr. 68 .

– Remove securing screw -arrow- for parking aid control unit J446- above relay carrier. – Remove data bus diagnostic interface -J533- ⇒ page 452 .

340

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♦ Remove the ignition key.

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Install in the reverse order of removal. When doing this, note the following:

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Installing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Detach the three connectors -arrows- and remove the parking aid control unit -J446- -1- upwards out of bracket. Installing Install in the reverse order of removal. When doing this, note the following: – Tighten bolt of parking aid control unit -J446- to 1.5 Nm.

14.7

Coding parking aid control unit -J446-

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

– Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body

♦ General body repairs ♦ Parking aid

♦ Parking aid functions ♦ Coding parking aid

Adjust optical display agen lksw Vo by

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Special tools and workshop equipment required

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14.8

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Procedure

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AG. Volkswagen AG d agen oes ksw not l o V gu by ara d nte ir se o eo h t u ra a c ss

AG.

14. Parking aid

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341

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure . Volkswa AG – Connect vehicle diagnosis, testing and information system - gen AG do agen es n ksw l VAS 5051B- . ot g o V

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e ris – In vehicle diagnosis, testing and information system -VAS tho u 5051B- , select „Guided fault finding“. a

ss

♦ General body repairs ♦ Parking aid

♦ Parking aid functions

♦ Adjust optical display

14.9

Removing and installing rear parking aid senders

Special tools and workshop equipment required ♦ Release tool -T10345-

Prote cted by

♦ Parking aid sender, rear right, inner -G335♦ Rear right centre parking aid sender -G205-

342

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AG.

♦ Parking aid sender, rear left, inner -G334-

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♦ Rear left centre parking aid sender -G204-

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Senders in rear bumper cover:

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♦ Body

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– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

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a oes ksw not 2010 ➤ , Jetta 2005 ➤ Golf Vol Variant 2007 ➤ , Golf Variant gu by ara d Electrical system - Edition 07.2010 e n is

♦ It is possible that the first software version of the parking aid

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es, in part or in w l purpos hole ercia , is n m ot com

control unit -J446- may display various sender designations due to the various levels of software. In this case allocation is as follows:

♦ Rear centre left parking aid sender -G204- is rear left parking

aid sender -G203-

♦ Rear left inner parking aid sender -G334- is rear centre left

parking aid sender -G204-

♦ Rear right inner parking aid sender -G335- is rear centre right

parking aid sender -G205-

♦ Rear centre right parking aid sender -G205- is rear right park‐

ing aid sender -G206-

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♦ Remove the ignition key.

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♦ Switch off ignition and all electrical consumers.

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Caution

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The removal and installation procedure is the same for all senders and is therefore described here for just one sender.

Removing – Remove rear bumper cover ⇒ General body repairs, exterior; Rep. gr. 63 . Caution

♦ The order for removing the senders must be adhered to under all circumstances. ♦ The sender may otherwise be damaged. Hairline cracks may occur if too much force is applied to the sender, caus‐ ing the sender to fail. ♦ First remove sender from bracket and then disconnect sender connector. – Release locking lugs -arrows- using release tool -T10345- and pull sender with connector still joined out of bumper cover.

14. Parking aid

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343

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ olkswagen AG Electrical system - Edition 07.2010 en AG. V – Disconnect connector -arrowInstalling

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Caution

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Install in the reverse order of removal. When doing this, note the following:

♦ Expanding the isolation ring must be avoided under all circumstances. ♦ Function problems may occur if a damaged isolation ring is used. ♦ Renew damaged isolation rings.

Note

♦ Senders are available in different forms and must be assigned r te o iva r rp fo

B - RRC - right centre C - RLC - left centre D - RL - left outer Note ♦ When mounting the sender, ensure that the isolation ring

(black silicone ring) is correctly mounted on the sender head and does not ride or roll up on insertion into the sender holder.

♦ During installation, both locking lugs of sender must engage

audibly into sender holder.

– After installing the sender, check that the sender is correctly seated in the bracket. Visible on the outer side of the bumper, dimension -a- of the ring gap between the sender head and the sender holder must be even all around.

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AG.

A - RL - right outer

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Assignment of parking aid senders on inside of rear bumper cov‐ er:

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tions of senders.

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♦ When installing senders, note position of electrical connec‐

thi sd o cu m en

to respective fitting location in bumper cover.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

14.10

Removing and installing front parking aid senders

Note ♦ The following illustrations show the removal and installation of

the front left parking aid sender.

♦ The removal and installation of the other parking aid senders

are carried out in the same way.

♦ Both exterior front left parking aid sender -G255- and front right

parking aid sender -G252- can also be removed through in‐ stallation aperture of fog light. Depending on equipment, re‐ move either front cover in bumper cover or fog light ⇒ page 297 . Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r Remove front bumper cover ⇒ General body repairs, exterior; o eo h t u ra a Rep. gr. 63 . c ss

Removing

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Caution es, in part or in w l purpos hole ercia , is n m ot com

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♦ The order for removing the senders must be adhered to under all circumstances.

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–

♦ The sender may otherwise be damaged. Hairline cracks may occur if too much force is applied to the sender, caus‐ ing the sender to fail. ♦ First remove sender from bracket and then disconnect sender connector. – Push fasteners -arrows- on sender holder -1- outwards.

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silicone ring) on the sender head does not remain in the sender or become lost. Prote cted by c o py rig ht. C op yi

♦ Expanding the isolation ring must be avoided under all cir‐

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cumstances.

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♦ When removing the sender, ensure the isolation ring (black

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Note

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– Pull sender -2- with connected wiring backwards out of sender holder.

14. Parking aid

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345

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Detach connector -2- and remove sender -1-. Installing

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Caution

rrectness of i t to the co n f o r m spec atio h re n in wit

♦ Expanding the isolation ring must be avoided under all circumstances. ♦ Function problems could occur if an incorrect or damaged isolation ring is used. ♦ Renew damaged isolation rings and always ensure that the correct isolation ring is fitted.

Note

As the front parking aid senders have sender heads of different lengths, isolation rings of different heights are also installed. – Check whether the correct isolation ring is installed on the sender head.

5.7 mm AG.

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– Renew the sender isolation ring -1-.

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Front parking aid senders

Isolation ring height dimen‐ sion -B-

– Assign senders to correct fitting location in bumper cover. Note ♦ Senders are available in different forms and must be assigned

to respective fitting location in bumper cover.

♦ When installing senders, note position of electrical connec‐

tions of senders.

Assignment of parking aid sender on inside of rear bumper cover: A - left outer B - left centre C - right centre D - right outer

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Type of sender

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Install in the reverse order following:

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e of removal. When doing this, note the nte s i r o eo h t u ra a c ss

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 olksw

C - right outer

Note

♦ When mounting the sender, make sure that the isolation ring

is correctly mounted on the sender head and does not ride or roll up on insertion into the sender holder.

♦ Both locking lugs of sender holder must audibly engage when

installing the sender.

14.11.1

Bonding sender holder in bumper cover

AG.

Bonding sender holder in bumper cover

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14.11

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– After installing the sender, check that the sender is correctly seated in the bracket. Visible on the outer side of the bumper, dimension -a- of the ring gap between the sender head and bumper cover must be even all around.

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D - left outer

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B - right centre (in radiator grille)

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A - left centre (in radiator grille)

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Assigning the sender holder to location on cover, from model year 2011:

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The bonding process for the sender retainers in the front and rear bumper covers is performed in the same manner. The bonding area on the inside of the bumper cover is marked as a field around the punched hole to assist in aligning the sender retainer during the bonding process. Ensure that the material temperature of the bumper cover and the sender holder lies between 15 ? and 25 ?.

14. Parking aid

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347

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Clean the marked bonding areas -1- on the inside of the bump‐ er cover thoroughly with isopropanol (isopropyl alcohol). – Apply adhesion promoter „Scotchmount 4298“ evenly to marked bonding area -1– Allow adhesion promoter to flash-off for approx. 5 minutes. . Volkswagen AG

AG – Note correct position for bonding the sender holder. agen ksw

Front bumper cover ⇒ page 346 Rear bumper cover ⇒ page 344

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– Align sender retainer -2- in marked bonding area -1- so that a uniform edge of approx. 3 mm is created. Note

Ensure that the cut-out for the sender connector in the sender holder is pointing in the correct direction as shown in the respec‐ tive allocation. The sender wiring is too short if the sender holder is fitted incorrectly. – Press sender holder -2- onto bumper cover for approx. 10 seconds using a high pressure.

The pressure and the period are critical for the bonding proper‐ ties!

Bonding sender holder in radiator grille Prote cted by

348

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AG.

Ensure when bonding the sender retainer in the radiator grille that the sender retainer is aligned centrally in the punched hole in the radiator grille as the sender holder does not have a shoulder. If the sender holder is not aligned exactly centrally in the punched hole in the radiator grille the isolation ring (black silicone ring) will be under pressure from the sender ring, once installed. This may adversely affect the function of the parking aid system. Ensure the material temperature of the radiator grille and the sender holder lies between 15 ? and 25 ?.

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c o p yri gh t. C op yi

14.11.2

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Note

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– Peel both protective foils off bonding surface of sender holder -2- until a grey surface appears.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Clean the bonding area on the inside of the radiator grille thor‐ oughly with isopropanol (isopropyl alcohol). 1-

Parking aid senders

2-

Decoupling ring

3-

Sender holder

4-

Bonding surface on inside of bumper

– Apply adhesion promoter „Scotchmount 4298“ evenly to bond‐ ing area around punched hole. – Allow adhesion promoter to flash-offn A for approx. minutes. olkswage5n A G. V

G do es n ot g ua ran tee or ac

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k Vol – Note correct position for bonding the sender holder. by d se

ri 347 Front bumper cover ⇒ page tho au

– Align sender head exactly centrally in punched hole in radiator grille. Note

If the sender head is not aligned exactly centrally in the punched hole in the radiator grille, the isolation ring (black silicone ring) will be under pressure from the sender ring, once installed, which may adversely affect the function of the parking aid system. – Firmly press sender holder onto radiator grille for approx. 10 seconds. Note

Renewing parking aid senders

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AG.

14.12

ht rig py Co t.

The pressure and the period are critical for the bonding proper‐ ties!

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urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e g n

– Peel both protective foils off bonding surface of sender holder -3- until a grey surface appears.

ility ab y li an pt ce

s – Insert sender -1- sinto sender holder -3- until both locking de‐ vices audibly engage.

If a new parking aid sender is installed, the sender head must be first painted in the colour of the bumper cover. The following pre‐ requisites must be adhered to when painting the senders to ensure the function of the parking aid system is not adversely affected. Painting senders – Remove isolation ring (black silicone ring) from new sender head.

14. Parking aid

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349

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Degrease black sender head -1- in area to be painted -2- with isopropanol (isopropyl alcohol). – Paint sender in area to be painted -2- in colour of bumper cov‐ er. Note

Dimension -B- for the painted area must not exceed 3 mm (plus maximum 2 mm). – Fit isolation ring (black silicone ring) on sender head again once paint has dried. Caution

♦ Expanding the isolation ring must be avoided under all circumstances. ♦ Function problems may occur if a damaged isolation ring is used. ♦ Renew damaged isolation rings.

14.13

Testing parking aid senders

This function can be used to check the following components via the parking aid control unit -J446- : ♦ Front left parking aid sender -G255♦ Front centre left parking aid sender -G254♦ Front centre right parking aid sender -G253♦ Front right parking aid sender -G252♦ Rear left parking aid sender -G203♦ Rear centre ♦ Rear centre

n AG. Volkswagen AG do es n wage ot g olks V ua left parking aid sender -G204-ed by ran ir s tee o h t or right parking aid sender -G205ac au s s urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t a itte iv du pr r o nl f e ng

Procedure

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♦ Rear right parking aid sender -G206-

rrectness of i t to the co nform spec a t ion h re wit in t his

– Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

♦ Parking aid senders

Rep. gr.94 - Lights, bulbs, switches - exterior

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do c um en

350

AG.

♦ Electrical components

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♦ Parking aid

Prote cted by c o py rig ht . C op yi

♦ General body repairs

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♦ Body

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

14.14

Removing and installing rear parking aid warning buzzer -H15- - saloon

Rear parking aid warning buzzer -H15- is attached to panel of rear shelf. It is accessible from the luggage compartment. Caution n AG. Volkswagen AG do es n wage ot g olks V y ua b d ran ise tee r o h t or u ac a ss

♦ Switch off ignition and all electrical consumers.

– Disconnect connector -1-.

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Removing

– Loosen expansion rivet -arrows- and remove rear parking aid warning buzzer -H15- from bracket. Installing

Installation is carried out in reverse order of removal.

Removing and installing rear parking aid warning buzzer -H15- - estate

The rear parking aid warning buzzer -H15- is located behind the rear right luggage compartment side panel trim near the seat belt mounting.

AG.

♦ Switch off ignition and all electrical consumers.

agen lksw Vo by

Prote cted by c o py rig h t . Co py i

Caution

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14.15

rrectness of i t to the co nform spec at i h re o n wit in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m m ot p r co erm o e t a itte v i r du p or nl f e g n

♦ Remove the ignition key.

♦ Remove the ignition key. Removing – Remove right luggage compartment side trim panel ⇒ General body repairs, interior; Rep. gr. 70 . – Disconnect connector -2-. – Remove spreader rivet -arrows- and remove rear parking aid warning buzzer -H15- -1-. Installing Installation is carried out in reverse order of removal. Note

Coding, basic setting and adaptation are not necessary if the rear parking aid warning buzzer -H15- is renewed.

14. Parking aid

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351

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ wagen AG. Volkswagen AG doe s no ks t gu Vol Electrical system - Edition 07.2010 by a ed ris ho t au ss

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Adjusting rear parking aid warning buz‐ zer -H15- volume urposes, in part or in wh ole, cial p is n mer m ot p o c r erm te o a itte ir v du p or nl f e ng

14.16

ran tee or ac

Special tools and workshop equipment required

Procedure

rrectness of i t to the co nform spec a t i h re o n in wit thi s

♦ Vehicle diagnosis, testing and information system -VAS 5051B-

♦ General body repairs ♦ Parking aid ♦ Parking aid functions ♦ Adjusting volume of rear parking aid warning buzzer

14.17

Adjusting rear parking aid warning buz‐ zer pitch -H15-

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

352

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AG.

♦ Body

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Prote cted by c o py rig ht. C op yi

– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

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– In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

do c um en

– Connect vehicle diagnosis, testing and information system VAS 5051B- .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Body ♦ General body repairs ♦ Parking aid ♦ Parking aid functions ♦ Adjusting pitch of rear parking aid warning buzzer

14.18

Removing and installing front parking aid warning buzzer -H22-

The front parking aid warning buzzer -H22- is located under the dash panel in the driver's footwell and is secured on the console AG. Volkswagen AG d for relay carrier. agen oes ksw n Caution

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Removing

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♦ Remove the ignition key.

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♦ Switch off ignition and all electrical consumers.

– Remove trim in driver's footwell ⇒ General body repairs, in‐ terior; Rep. gr. 68 . – Release both spreader rivets -arrows-. – Detach connector -1- and remove front parking aid warning buzzer -H22- -2- from vehicle. Installing

Installation is carried out in reverse order of removal.

r te o iva r rp fo

Special tools and workshop equipment required

AG.

Adjusting front parking aid warning buz‐ zer -H22- volume

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

14.19

ht rig py Co t.

ng

Coding, basic setting and adaption are not necessary if the front parking aid warning buzzer -H22- is renewed.

thi sd o cu m en

Note

♦ Vehicle diagnosis, testing and information system -VAS 5051B-

This function can be used to adjust the volume of the front parking aid warning buzzer -H22- .

14. Parking aid

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353

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ General body repairs ♦ Park assist steering ♦ Park assist steering functions ♦ Adjusting volume of front parking aid warning buzzer

14.20

Adjusting front parking aid warning buz‐ zer pitch -H22-

Special tools and workshop equipment required

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♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure

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pe rm itte d

This function can be used to adjust the pitch of the front parking aid warning buzzer -H22- . – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

♦ Body ♦ General body repairs ♦ Park assist steering

♦ Park assist steering functions

♦ Adjusting pitch of front parking aid warning buzzer ng

Parking aid final control diagnosis b y c op yri gh t . Co py i

Special tools and workshop equipment required

Prote cted

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14.21

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– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

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♦ Body

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♦ General body repairs

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ss select „Functions/component“ and the fol‐ – Using GoTo button, lowing menu options in succession:

♦ Parking aid ♦ Parking aid functions ♦ Parking aid final control diagnosis

14.22

Checking parking aid button -E266-

Special tools and workshop equipment required

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♦ Vehicle diagnosis, testing and information system -VAS 5051B-

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Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ General body repairs ♦ Parking aid ♦ Electrical components of parking aid 14. Parking aid

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355

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Parking aid button

AG.

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Rep. gr.94 - Lights, bulbs, switches - exterior

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356

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

15

Park assist steering

15.1

General description Note

♦ When handling complaints, it is essential to understand the

function and operation of the park assist steering system.

♦ Additional information ⇒ Owner's Manual Functioning

The following conditions lead to abortion of the parking process with park assist steering: ♦ The park assist steering system is switched off via the park assist steering button -E581- . ♦ Ignition is switched off

♦ Parking speed too high (greater than 7 km/h) ♦ Steering intervention by driver during parking process ♦ Disengagement of reverse gear

♦ Vehicle standstill time limit exceeded (approx. 30 seconds) ♦ ESP switched off or ESP intervention

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♦ Sensors detect a status which endangers secure determina‐ tion of the vehicle position.

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♦ Front parking aid is switched on.

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♦ Trailer on the vehicle

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♦ TCS intervention

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The park assist steering supports the driver when reversing into a parallel parking space on the driver or passenger side. When the park assist steering is activated and the vehicle drives by at a speed of less than 35 km/h, the side of the road is measured by ultrasonic sensors searching for a suitable parking space. Once AG. Volkswagen AG d a parking space has been reliably detected, the park assist agen steer‐ oes ksw not l o V parking space ing requests the driver to continue passing bybythe gu ara d e until the vehicle is in a position from whichrisrapid parking is pos‐ nte eo ho park assist steering t sible. When reverse gear is engaged, the u ra a c undertakes lateral guidance of the vehicle by actuating the EPS ss (electronic power steering) and steers the vehicle into the parking space in one movement along a calculated, nominal path. The driver maintains operation of the pedals (accelerator, clutch, brake) and longitudinal vehicle guidance, and therefore deter‐ mines the parking speed. During the parking process, the park assist steering sensors are used together with the parking aid senders to monitor proximity.

♦ System malfunction

15. Park assist steering

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357

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 WARNING

♦ Responsibility during parking is borne by the driver. ♦ The park assist steering system cannot replace the driv‐ er's attentiveness. ♦ The sensors have blind spots, in which persons and ob‐ jects can not be registered. ♦ Pay particular attention to small children and animals, as these are not always detected by the sensors. The park assist steering system consists of: ♦ Park assist steering control unit -J791♦ Front left sender for park assist steering on left side of vehicle -G568♦ Front left parking aid sender -G255♦ Front centre left parking aid sender -G254n AG. Volkswagen AG do ♦ Front centre right parking aid sender -G253e wage ks Vol

by ♦ Front right parking aid sender -G252ed

is or

♦ Park assist steering button -E581♦ Parking aid button -E266-

Fault detection and fault display: The park assist steering system is equipped with self-diagnosis. For fault finding, use vehicle diagnosis, testing and information system -VAS 5051B- in „Guided fault finding“ mode. To check the park assist steering system as a whole, perform final control diagnosis ⇒ page 362 .

AG.

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Rep. gr.94 - Lights, bulbs, switches - exterior

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♦ Front parking aid warning buzzer -H22-

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th ♦ Front right sender for park assist steering on right side of ve‐ au ss hicle -G569-

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Assembly overview - park assist steering

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2 - Front left parking aid sender -G255❑ In front bumper cover ❑ Removing and installing ⇒ page 363 ❑ Checking ⇒ page 365 ❑ Renew sender and sender holder in the event of repair ⇒ page 347 .

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1 - Front left sender for park assist steering on left side of vehicle -G568❑ In front bumper cover ❑ Removing and installing ⇒ page 363 ❑ Checking ⇒ page 365 ❑ Renewing ⇒ page 366 ❑ Renew sender and sender holder in the event of repair ⇒ page 347 .

ility ab y li an pt ce

15.2

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3 - Front centre left parking aid sender -G254❑ In front bumper cover ❑ Removing and installing ⇒ page 363 ❑ Checking ⇒ page 365 ❑ Renew sender and sender holder in the event of repair ⇒ page 347 . 4 - Front centre right parking aid sender -G253❑ In front bumper cover ❑ Removing and installing ⇒ page 363 ❑ Checking ⇒ page 365 ❑ Renew sender and sender holder in the event of repair ⇒ page 347 . 5 - Front right parking aid sender -G252❑ In front bumper cover ❑ Removing and installing ⇒ page 363 ❑ Checking ⇒ page 365 ❑ Renew sender and sender holder in the event of repair ⇒ page 347 . 6 - Front right sender for park assist steering on right side of vehicle -G569❑ In front bumper cover ❑ Removing and installing ⇒ page 363 ❑ Checking ⇒ page 365 ❑ Renewing ⇒ page 366 ❑ Renew sender and sender holder in the event of repair ⇒ page 347 . 7 - Front parking aid warning buzzer -H22❑ In driver's footwell, on relay carrier of dash panel 15. Park assist steering

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ❑ Removing and installing ⇒ page 367 ❑ Adjusting volume ⇒ page 368 ❑ Adjusting pitch ⇒ page 368 8 - Parking aid button -E266- / park assist steering button -E581❑ In centre console storage compartment next to gear lever ❑ Removing and installing ⇒ page 418 ❑ Checking park assist steering button -E581- ⇒ page 370 ❑ Checking parking aid button -E266- ⇒ page 371 9 - Park assist steering control unit -J791❑ In driver's footwell, above relay carrier ❑ Removing and installing (left-hand drive vehicle) ⇒ page 360 ❑ Removing and installing (right-hand drive vehicle) ⇒ page 361 ❑ Coding ⇒ page 362 ❑ Final control diagnosis ⇒ page 362 . AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r o eo h t u ra a c located ss in the driv‐

15.3

Park assist steering control unit -J791urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e g n

Removing and installing park assist steering control unit -J791- (left-hand drive vehicle)

The park assist steering control unit -J791- is located in the driv‐ er's footwell, above the relay carrier. Caution

♦ Switch off ignition and all electrical consumers.

Removing

– Remove trim in driver's footwell ⇒ General body repairs, in‐ terior; Rep. gr. 68 .

Rep. gr.94 - Lights, bulbs, switches - exterior

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Prote cted by

360

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– Remove windscreen wiper system ⇒ page 183 .

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– Remove securing screw -arrow- for park assist steering con‐ trol unit -J791- above relay carrier.

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♦ Remove the ignition key.

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15.3.1

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The park assist steering control unit -J791- is er's footwell, above the relay carrier. In vehicles with parking aid, the parking aid functions are simultaneously controlled by the park assist steering control unit -J791- ( parking aid control unit J446- ).

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove the three nuts -arrows- and remove cover -1-.

– Tighten bolt of park assist steering control unit -J791- to 1.5 Nm.

15.3.2

Removing and installing park assist steering control unit -J791- (right-hand drive vehicle)

The park assist steering control unit -J791- is located in the driv‐ er's footwell, above the relay carrier. Caution

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♦ Remove the ignition key.

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Removing

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♦ Switch off ignition and all electrical consumers.

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Install in the reverse order of removal. When doing this, note the following:

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AG. Volkswagen AG d agen oes ksw n l o V – Detach the three connectorsby-arrowsand remove the park ot gua d ran e s assist steering control unit tee ri -J791- -1- upwards out of bracket. ho t or u ac a Installing ss

– Remove trim in driver's footwell ⇒ General body repairs, in‐ terior; Rep. gr. 68 . – Remove securing screw -arrow- for park assist steering con‐ trol unit -J791- above relay carrier. – Remove data bus diagnostic interface -J533- ⇒ page 452 .

15. Park assist steering

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361

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Detach the three connectors -arrows- and remove the park assist steering control unit -J791- -1- upwards out of bracket. Installing Install in the reverse order of removal. When doing this, note the following: – Tighten bolt of park assist steering control unit -J791- to 1.5 Nm.

15.3.3

Coding park assist steering control unit -J791-

Special tools and workshop equipment required

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t a itte v i r d p

– Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

♦ Coding park assist steering

15.3.4

park assist steering control unit -J791final control diagnosis

Special tools and workshop equipment required

362

Rep. gr.94 - Lights, bulbs, switches - exterior

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AG.

♦ Park assist steering functions

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♦ Park assist steering

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♦ General body repairs

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♦ Body

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– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

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Procedure

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♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure

5051B- , select „Guided fault finding“. pe rm itte d

♦ Body

♦ General body repairs ♦ Park assist steering ♦ Park assist steering functions ♦ Park assist steering final control diagnosis

15.4

Park assist steering senders

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The following park assist steering senders are located in the front bumper cover:

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Park assist steering senders are installed in front bumper cover. The two park assist steering senders are mounted at the outer‐ most, lateral positions of the bumper cover, and are used to measure proximity during the parking process, together with the parking aid senders.

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– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

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–

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♦ Front left sender for park assist steering on left side of vehicle -G568agen lksw Vo by

♦ Front right sender for park assist steering on right side of ve‐ hicle -G569AG.

15.4.1

Removing and installing park assist steering senders Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Remove front bumper cover ⇒ General body repairs, exterior; Rep. gr. 63 .

15. Park assist steering

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363

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Caution

♦ The order for removing the senders must be adhered to under all circumstances. ♦ The sender may otherwise be damaged. Hairline cracks may occur if too much force is applied to the sender, caus‐ ing the sender to fail. ♦ First remove sender from bracket and then disconnect sender connector. – Push fasteners -arrows- on sender holder -1- outwards. – Pull sender -2- with connected wiring backwards out of sender holder. Note ♦ When removing the sender, make sure that the isolation ring

(black silicone ring) on the sender head does not remain in the sender or become lost. G. Volkswage nA wage

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olksavoided under all cir‐ ♦ Expanding the isolation ring musty Vbe

cumstances.

Installing

Install in the reverse order of removal. When doing this, note the following: Caution

Function problems could occur if an incorrect or damaged iso‐ lation ring is used. Expanding the isolation ring must be avoided under all circum‐ stances. Renew damaged isolation rings and always ensure that the correct isolation ring is fitted.

As the front parking aid sender and the park assist steering send‐ ers have sender heads of different lengths, isolation rings of different heights are also installed. Prote cted by

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AG.

Rep. gr.94 - Lights, bulbs, switches - exterior

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364

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Note

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– Detach connector -2- and remove sender -1-.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Check whether the correct isolation ring is installed on the sender head. Type of sender

Isolation ring height dimen‐ sion -B-

Front parking aid senders Park assist steering senders

5.7 mm 9.05 mm

– Renew the sender isolation ring -1-. Note . Volkswagen AG gen AG does not gu ara nte eo ra c

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Assignment of senders on inside of front bumper cover: pe rm itte d

A - FLS - bracket for front left sender for park assist steering on left side of vehicle -G568-

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Note

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B - FRS - bracket for front right sender for park assist steering on right side of vehicle -G569-

♦ When mounting the sender, make sure that the isolation ring

is correctly mounted on the sender head and does not ride or roll up on insertion into the sender holder.

♦ Both locking lugs of sender holder must audibly engage when

installing the sender.

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15.4.2

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– After installing the sender, check that the sender is correctly seated in the bracket. Visible on the outer side of the bumper, dimension -a- of the ring gap between the sender head and bumper cover must be even all around.

Checking parking aid sender/park assist steering sender

Special tools and workshop equipment required

15. Park assist steering

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365

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

This function can be used to check the following components via the park assist steering control unit -J791- : ♦ Rear left parking aid sender -G203♦ Rear centre left parking aid sender -G204♦ Rear centre right parking aid sender -G205♦ Rear right parking aid sender -G206♦ Front left sender for park assist steering on left side of vehicle -G568♦ Front left parking aid sender -G255♦ Front centre left parking aid sender -G254♦ Front centre right parking aid sender -G253♦ Front right parking aid sender -G252♦ Front right sender for park assist steering on right side of ve‐ hicle -G569AG. Volkswagen Procedure

-

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– In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ General body repairs ♦ Park assist steering

♦ Park assist steering electrical components ♦ Parking aid sender/park assist steering sender

15.5

Renewing park assist steering sender

If a new park assist steering sender is installed, the sender head must be first painted in the colour of the bumper cover. The fol‐ lowing prerequisites must be adhered to when painting the send‐ ers to ensure the function of the parking aid system is not adversely affected.

– Remove isolation ring (black silicone ring) from new sender head.

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366

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Painting senders

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15.5.1

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– Connect vehicle diagnosis, testing VAS 5051B- .

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Degrease black sender head -1- in area to be painted -2- with AG. Volkswagen AG d isopropanol (isopropyl alcohol). agen oes ksw n ol yV

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ara d bbe painted -2- in colour of bumper cov‐ – Paint sender in areaiseto nte r o eo er. h t u

ra c

– Fit isolation ring (black silicone ring) on sender head again once paint has dried. Caution

♦ Expanding the isolation ring must be avoided under all circumstances. ♦ Function problems may occur if a damaged isolation ring is used. ♦ Renew damaged isolation rings.

Front parking aid warning buzzer -H22-

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15.6

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Dimension -B- for the painted area must not exceed 3 mm (plus maximum 2 mm).

do c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm te o a itte ir v du p or nl f e ng

Note

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The front parking aid warning buzzer -H22- is located in the driver side footwell, behind the left dash panel relay carrier. agen lksw Vo by

Removing and installing front parking aid warning buzzer -H22AG.

15.6.1

The front parking aid warning buzzer -H22- is located under the dash panel in the driver's footwell and is secured on the console for relay carrier. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Remove trim in driver's footwell ⇒ General body repairs, in‐ terior; Rep. gr. 68 . – Release both spreader rivets -arrows-. – Release and disconnect connector -1- and remove front park‐ ing aid warning buzzer -H22- -2- from vehicle. Installing Installation is carried out in reverse order of removal. Note

Coding, basic setting and adaption are not necessary if the front parking aid warning buzzer -H22- is renewed.

15. Park assist steering

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367

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

15.6.2

Adjusting front parking aid warning buz‐ zer -H22- volume

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ General body repairs ♦ Park assist steering ♦ Park assist steering functions ♦ Adjusting volume of front parking aid warning buzzer

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15.6.3

oes w not Adjusting front parking aid warning buz‐ olks gu yV b ara d e nte is zer pitch -H22r e ho

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– Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

Prote cted

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Rep. gr.94 - Lights, bulbs, switches - exterior

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– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

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urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t a itte riv du p r o nl f e ng

♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure

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Special tools and workshop ss equipment required

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Body ♦ General body repairs ♦ Park assist steering ♦ Park assist steering functions ♦ Adjusting pitch of front parking aid warning buzzer

15.7

Rear parking aid warning buzzer -H15-

On vehicles with park assist steering, the parking aid functions are controlled by the park assist steering control unit -J791- . For this reason, adaptations to the rear parking aid warning buzzer H15- are carried out via the park assist steering control unit J791- .

15.7.1

Removing and installing rear parking aid warning buzzer -H15-

Removing and installing rear parking aid warning buzzer -H15⇒ page 351

15.7.2

Adjusting rear parking aid warning buz‐ zer -H15- volume

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure

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– Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ General body repairs ♦ Park assist steering functions ♦ Adjusting volume of rear parking aid warning buzzer

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Adjusting rear parking aid warning buz‐ zer pitch -H15agen lksw Vo by

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15.7.3

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♦ Park assist steering

Special tools and workshop equipment required

15. Park assist steering

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369

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ General body repairs ♦ Park assist steering ♦ Park assist steering functions ♦ Adjusting pitch of rear parking aid warning buzzer

n AG. Volkswagen AG do es n wage ot g olks V y ua b d ran ise tee r o h t or u The park assist steering button -E266- / parking aid button -E581ac a ss of are located in the centre console storage compartment in front

Park assist steering/parking aid button

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15.8

the gear lever. The buttons cannot be disassembled.

15.8.1

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Removing and installing parking aid/ park assist steering button

Removal and installation of the buttons are carried out in the same way for all buttons in the centre console storage compartment and are described in chapter ⇒ page 418 .

15.8.2

Checking park assist steering button E581-

Special tools and workshop equipment required

♦ Vehicle diagnosis, testing and information system -VAS 5051B-

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Rep. gr.94 - Lights, bulbs, switches - exterior

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370

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ General body repairs ♦ Park assist steering ♦ Park assist steering electrical components ♦ Park assist steering button

15.8.3

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Checking parking aid button -E266-

♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure

– Connect vehicle diagnosis, testing and information system VAS 5051B- .

♦ General body repairs

AG.

♦ Body

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– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

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– In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

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Special tools and workshop equipment required

♦ Park assist steering ♦ Park assist steering electrical components ♦ Parking aid button

15. Park assist steering

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371

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

16

Reversing camera system

16.1

General description Note

♦ When handling complaints, it is essential to understand the

function and operation of the reversing camera system.

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♦ Additional information ⇒ Owner's Manual Functioning

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The reversing camera system supports ing by providing the driver with an image of the traffic situation behind the vehicle on the radio/navigation system display. The system is available as an option.

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The system is activated when reverse gear is engaged, even if the radio/navigation system is switched off. The reversing camera system consists of the following compo‐ nents: ♦ Reversing camera -R189-

♦ Control unit with display unit for radio and navigation -J503♦ Steering wheel with steering angle sender -G85Note

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AG.

For fault finding, use vehicle diagnosis, testing and information system -VAS 5051B- in „Guided fault finding“ mode.

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The reversing camera system is equipped with self-diagnosis.

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Fault detection and fault display

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Installation of an additional number plate carrier is not permissible on vehicles with reversing camera system as this would impair the function of the reversing camera. The light of the number plate could also be impaired.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

16.2

Assembly overview – reversing camera system

1 - Control unit with display unit for radio and navigation -J503❑ In centre console at front. ❑ Removing and installing ⇒ Communication; Rep. gr. 91

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16.3.1

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The reversing camera -R189- is installed in the handle button of the rear lid. To remove reversing camera -R189- , first remove handle button from rear lid. The reversing camera -R189- can then be removed from handle button.

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Removing and installing reversing cam‐ era -R189-

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16.3

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2 - Reversing camera -R189❑ In handle button of rear lid ❑ Removing and installing ⇒ page 373 ❑ Specified torque of nuts: 6 Nm ❑ Calibrating reversing camera system ⇒ page 375

Removing and installing handle button with reversing camera -R189-

Special tools and workshop equipment required

16. Reversing camera system

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373

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♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. r te o iva r rp fo

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Remove trim of rear lid ⇒ General body repairs, interior; Rep. gr. 70 . – Open wire bracket from wiring harness of reversing camera R189- in connector area and remove both wires.

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– Disconnect connectors -1- and -2-. AG.

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– Remove both nuts -arrows-. – Detach connector -4-. – Remove the handle button with reversing camera -R189- -3from rear lid. Remove reversing camera -R189- from handle button ⇒ page 375 . Installing Install in the reverse order of removal. When doing this, note the following: – Tighten all threaded connections to specified torques ⇒ page 373 . – Secure wiring of reversing camera -R189- with wiring retainer to avoid rattling. – After installation, clean reversing camera -R189- lens with a lint-free cloth. – Recalibrate system ⇒ page 375 .

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Removing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

16.3.2

Removing and installing reversing cam‐ era -R189- from handle button

Removing

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– Pull reversing camera -R189- -1- out of lower part of handle button -2-. Installing

Installation is carried out in reverse order of removal.

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Calibrating reversing camera system AG.

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16.4

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– Release locking lugs

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Reversing camera -R189- system may have to be recalibrated following repair work on the vehicle. In detail, this is the case after: ♦ Removing and installing reversing camera -R189♦ Accident repairs on rear lid ♦ After vehicle alignment ♦ Repairs to front or rear axle Extensive preliminary work is required before actual calibration can be carried out using vehicle diagnosis, testing and information system -VAS 5051B- . This is described in the following. Special tools and workshop equipment required ♦ Calibration unit -VAS 6350-

16. Reversing camera system

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375

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

16.4.1

Preparatory measures for calibration

To carry out calibration, vehicle must be positioned on a firm, level surface. It is not permissible for anybody to be inside vehicle dur‐ ing measurement. Vehicle must not be moved during measure‐ ment, and opening and closing vehicle doors is prohibited. – Connect vehicle diagnosis, testing and information system VAS 5051B- . – Set steering wheel sender -G85- to 0 position (wheels straight ahead). Overview of measuring setup 1 - Wheel centre mounting VAS 6350/12 - Wheel centre mounting VAS 6350/13 - Right bracket ❑ Spacing laser -VAS 6350/2- mounting

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Assembling, setting-up calibration unit -VAS 6350/4-

– Position paddles on both wheel centre mountings -VAS 6350/1- and secure with clamping bolts.

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AG.

– Secure three wheel bolt adapters in each hole circle of wheel centre mounting -VAS 6350/1- .

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9 - Calibration unit -VAS 6350/4❑ Distance between angle of calibration unit -VAS 6350/4- and wheel cen‐ tre mounting -VAS 6350/1- : 1.20 m to 1.70 m -dimension A-

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8 - Left bracket ❑ Spacing laser -VAS 6350/2- mounting

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7 - Spirit level on calibration unit ❑ For checking horizontal position

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6 - Spacing laser -VAS 6350/2❑ Notes on operation ⇒ Owner's manual

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5 - Plastic foot ❑ Three on underbody ❑ Adjustable for setting the horizontal position

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4 - Linear laser -VAS 6350/3❑ Switching on and off ⇒ Owner's manual

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Insert wheel centre mountings -VAS 6350/1- into wheel bolts of rear wheels. Wheel centre mountings -VAS 6350/1- are positioned and secured in the adapters by the »O-rings«. Note

Set wheel centre mountings -VAS 6350/1- against wheels so that no »theft-inhibiting wheel bolts« are connected to wheel bolt adapters. AG. Volkswagen A

– Position the calibration device -VAS 6350/4- horizontally. Do this by turning the plastic feet under the calibration unit -VAS 6350/4- until the air bubble in the spirit level is precisely in the centre of the indicator -arrow-.

– Switch on the linear laser -VAS 6350/3- on calibration unit VAS 6350/4- -1- and align the entire calibration unit -VAS 6350/4- so that the laser beam -2- hits the rear end of the ve‐ hicle centrally above the VW logo.

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– Position calibration device -VAS 6350/4- behind vehicle at a distance of 1.20 m to 1.70 m to the angle brackets of the cal‐ ibration device -VAS 6350/4- and the paddles on the wheel centre mountings -VAS 6350/1- , see -dimension A⇒ Item 9 (page 376) .

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– Switch on the spacing laser -VAS 6350/2- with the ON button. The following display appears and the laser is activated:

16. Reversing camera system

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377

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Hold spacing laser -VAS 6350/2- -2- as shown in illustration flush against bracket on one side of calibration unit -VAS 6350/4- so that spacing laser -VAS 6350/2- lies firmly against bracket.

If this is not the case, adjust paddles accordingly on wheel mount‐ ing -VAS 6350/1- using clamping bolts.

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– Hold spacing laser -VAS 6350/2- in bracket on calibration de‐ vice -VAS 6350/4- while laser beam is visible on paddle. Now briefly press the ON button to measure distance. The following appears in the display: The distance is shown on the display in „metres“. – Note the measured value. – Repeat measuring process in same manner for other rear wheel on other side of calibration unit -VAS 6350/4- . cop yri gh t . Co py i

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When adjusting the calibration unit -VAS 6350/4- , ensure that the laser beam of the linear laser -VAS 6350/3- continues to hit the vehicle centrally above the VW logo and that the spirit level indi‐ cator remains in the centre. Adjust accordingly if required. AG.

The distance measured must be entered in „millimetres“ in the vehicle diagnostic, testing and information system -VAS 5051Bduring calibration. Calibrate reversing camera system ⇒ page 378 .

16.4.2

Calibrating reversing camera system

Special tools and workshop equipment required

378

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Measured distance value must be identical on both sides. If value is not identical, adjust calibration unit -VAS 6350/4- until values on both sides are identical.

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–

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Note

Note the points regarding preparatory work for calibration ⇒ page 376 . – Connect vehicle diagnosis, testing and information system . Volkswagen AG gen AG VAS 5051B- . does a w s k Vol

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ss – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

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♦ 01 - On board diagnostic capable system ♦ Reversing camera system ♦ Reversing camera functions ♦ Carry out reversing camera calibration

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From this point on, guidance during the calibration process will be provided by the vehicle diagnosis, testing and information system -VAS 5051B- .

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♦ Electrical system

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16. Reversing camera system

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379

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

17

Removing and installing trailer socket -U10Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Remove bolts -arrows-. – Remove trailer socket -U10- from retaining plate.

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– Push connectors -2- in -direction of arrow- out of trailer socket -U10- -1-.

– Unlock securing tabs -arrows- and then unlock retaining clips -1- and -3- to -5-. Prote cted by c o py rig ht . C op yi

Installing

Carry out installation in the reverse sequence, noting the follow‐ ing:

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Note

Be especially careful that seals -1- and -3- are not damaged.

380

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– Remove holding cage from connectors -2-.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Push connectors -4- in until they can be heard to engage in holding cage -2-. olkswagen AG en AG. V

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Pin assignment of trailer socket -U10-

3-

Terminal 31

4-

Terminal RTS (right turn signal)

5-

Terminal 58R (right tail light)

6-

Terminal 54 (brake light)

7-

Klemme 58L (left tail light)

8-

Terminal RF (reversing light)

9-

Terminal 15

10 - Reserved for terminal 30 11 - Reserved for terminal 31

AG.

Terminal NSL (rear fog lamp)

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Terminal LTS (left turn signal)

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12 - Not assigned 13 - Terminal 31

17. Removing and installing trailer socket U10

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381

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

Lights, bulbs, switches - interior

1

Lights and switches in engine com‐ partment

Jetta, Bora and Golf Variant do not have an engine compartment light -W27- .

1.1

Removing and installing bonnet contact switch -F266-

The bonnet contact switch -F266- is integrated in the bonnet lock and cannot be replaced as a single item. If there is a defect, the complete lid lock must be renewed ⇒ General body repairs, exterior; Rep. gr. 55 .

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Rep. gr.96 - Lights, bulbs, switches - interior

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382

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Note

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96 –

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

2

Lights and switches in dash panel

2.1

Removing and installing light switch E1-

The following components are integrated into the light switch E1- : ♦ Fog light switch -E7♦ Rear fog light switch -E18♦ Bulb for illumination of light switch -L9Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

– Turn rotary grip of light switch -E1- to position „0“. – Push in rotary grip of light switch -E1- -arrow 1- and turn it slightly to the right -arrow 2-.

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– Fit connector to light switch -E1- .

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– Disconnect connector -arrow-.

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– Hold rotary knob in this position and pull on rotary knob to re‐ move light switch -E1- from dash panel -arrow 3-.

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2. Lights and switches in dash panel

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383

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Hold light switch -E1- , press in rotary knob of light switch -E1-arrow 1- and turn slightly to right -arrow 2-. – Hold rotary grip in this position and insert light switch -E1- into dash panel -arrow 3- using rotary grip.

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2.2

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– Turn grip of light switch to position „0“, release light switch -E1- .

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Removing and installing glove compart‐ ment light -W6-

Special tools and workshop equipment required

Removing – Open glove box. – Use removal wedge -VAS 3409- to carefully prise out glove compartment light -W6- .

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♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape.

AG.

♦ Remove the ignition key.

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♦ Switch off ignition and all electrical consumers.

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Renewing bulb:

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– Release locking lugs -1- and remove heat shield -2- from lens of glove compartment light -W6- .

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– Carefully lever bulb out of holder.

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– Disconnect connector

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– Renew glass-base bulb (12 V/5 W). Caution

♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over. Installing Install in the reverse order of removal. When doing this, note the following: – Check function of glove compartment switch -E26- . When the lid is closed, the glove compartment light -W6- should not be on.

2.3

Removing and installing glove compart‐ ment light switch -E26-

The switch for glove compartment light -E26- can be found at the rear of the glove compartment. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Remove glove compartment ⇒ General body repairs, interior; Rep. gr. 68 . 2. Lights and switches in dash panel

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385

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Release locking lug -1- and push glove compartment light switch -E26- out of guide rail -arrow-. Installing Installation is carried out in reverse order of removal.

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Removing and installing regulator for switch and instrument illumination -E20-

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Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. ♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape. Removing

– Remove light switch -E1- ⇒ page 383 . – Removing driver side storage compartment ⇒ General body repairs, interior; Rep. gr. 68 . – Disconnect connector -arrow-.

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Installing Installation is carried out in reverse order of removal.

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– Release locking lugs -arrows- and remove regulator for switch and instrument illumination -E20- .

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2.4

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

2.5

Removing and installing warning lamp for airbag deactivated on front passen‐ ger side -K145WARNING

Comply with the safety precautions when working on the airbag ⇒ General body repairs, interior; Rep. gr. 69 .

♦ Remove the ignition key.

♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape.

Removing – Remove centre vents ⇒ Heating, air conditioning system; Rep. gr. 80 . – Disconnect connectors -arrows-.

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♦ Switch off ignition and all electrical consumers.

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– Release locking lugs -arrows- and remove airbag warning lamp from passenger side -K145- . Installing Installation is carried out in reverse order of removal.

2. Lights and switches in dash panel

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387

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

2.6

Removing and installing hazard warning light switch -E3Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

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– Disconnect connectors -arrows-.

– Release locking lugs -arrows- and remove hazard warning light switch -E3- .

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2.7

Removing and installing footwell lights

Left footwell light -W9- / right footwell light -W10- are removed and installed in same way and description is only given for one. Special tools and workshop equipment required

388

Rep. gr.96 - Lights, bulbs, switches - interior

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AG.

Installation is carried out in reverse order of removal.

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Installing

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– Remove centre vents ⇒ Heating, air conditioning system; Rep. gr. 80 .

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➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

♦ Removal wedge -VAS 3409-

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Caution

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♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape.

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♦ Remove the ignition key.

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♦ Switch off ignition and all electrical consumers.

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Removing – Use removal wedge -VAS 3409- to prise left footwell light -W9out of trim beneath dash panel.

– Disconnect connector -arrow-. Renewing bulb:

2. Lights and switches in dash panel

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389

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Release locking lugs -1- and remove heat shield -2- from lens of footwell light on left -W9- .

– Carefully lever bulb out of holder. – Renew glass-base bulb (12 V/5 W). Caution

♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over. Installing

Installation is carried out in reverse order of removal.

Comply with the safety precautions when working on the airbag ⇒ General body repairs, interior; Rep. gr. 69 .

Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Remove glove compartment ⇒ General body repairs, interior; Rep. gr. 68 .

390

Rep. gr.96 - Lights, bulbs, switches - interior

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AG.

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WARNING

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Removing and installing key operated switch to deactivate front passenger side airbag -E224-

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2.8

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Disconnect connector -arrow-.

– Release locking lugs -arrows- and remove front passenger side airbag deactivation key switch -E224- . Installing

Installation is carried out in reverse order of removal.

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2. Lights and switches in dash panel

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391

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

3

Lights and switches in front doors and B-pillar

3.1

Removing and installing window regula‐ tor switch in front passenger door E107Note

The window regulator switch in front passenger door -E107- has an integrated button illumination bulb -L76- , which cannot be re‐ placed separately. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

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Removing

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– Remove upper part of handle recess from door handle ⇒ General body repairs, interior; Rep. gr. 70 . – Disconnect connector -arrow-.

Prote cted by

392

Rep. gr.96 - Lights, bulbs, switches - interior

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AG.

– When installing, make sure you hear the four locking lugs click into place.

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Installing

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– Release the four locking lugs -arrows- and remove window regulator switch in front passenger door -E107- from installa‐ tion frame.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

3.2

Removing and installing switch module for mirror adjustment on driver side

Mirror adjustment switch module - driver side (depending on equipment) ♦ Mirror adjustment switch -E43♦ Mirror adjustment changeover switch -E48♦ Exterior mirror heater button -E231♦ Fold-in mirror switch -E263♦ Mirror adjustment switch illumination bulb -L78-

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The above mentioned components cannot be renewed individu‐ ally.

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Caution

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– In case of a defect, renew switch module for mirror adjustment - driver side.

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape.

AG.

Installing

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– Release locking lugs -arrows- and remove the switch module from the installation frame.

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– Unclip installation frame of switch out of trim.

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– Remove switch module for window regulator - driver side ⇒ page 395 .

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Removing

Installation is carried out in reverse order of removal.

3.3

Removing and installing driver side in‐ terior locking button for central locking system -E308Note

The driver side interior locking button for central locking system E308- has an integrated button illumination bulb -L76- , which cannot be replaced separately.

3. Lights and switches in front doors and B-pillar

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393

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Caution

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– Remove door trim ⇒ General body repairs, interior; Rep. gr. 70 . – Detach connector -1- and remove bolts -2-. – Remove inside door handle together with driver side interior locking button for central locking system -E308- out of door trim.

Installation is carried out in reverse order of removal. AG.

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3.4

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Installing

Components - front door locks

Door lock - driver side (depending on equipment) ♦ Driver door contact switch -F2♦ Driver side central locking lock unit -F220♦ Driver door central locking motor -V56♦ Driver door central locking deadlock function motor -V161Door lock - front passenger side (depending on equipment) ♦ Front passenger door contact switch -F3♦ Front passenger side central locking lock unit -F221♦ Front passenger side central locking motor -V57♦ Front passenger door central locking deadlock function motor -V162-

394

Rep. gr.96 - Lights, bulbs, switches - interior

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– Release locking lugs -arrows- and remove driver side interior central locking button -E308- from installation frame.

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Removing

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 The above mentioned components cannot be renewed individu‐ ally. – In case of a defect, renew respective door lock ⇒ General body repairs, exterior; Rep. gr. 57 .

3.5

Removing and installing switch module for driver side window regulator

Window regulator components - driver page (4 doors) ♦ Front left window regulator switch -E40♦ Rear left window regulator switch, in driver door -E53♦ Rear right window regulator switch, in driver door -E55♦ Front right window regulator switch, in driver door -E81♦ Childproof lock button -E318♦ Button illumination bulb -L76Window regulator components - driver page (2 doors) ♦ Front left window regulator switch -E40♦ Front right window regulator switch, in driver door -E81♦ Button illumination bulb -L76The above mentioned components cannot be renewed individu‐ ally. – In case of a defect, renew corresponding switch module.

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Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

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3. Lights and switches in front doors and B-pillar

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395

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Caution

DO NOT attempt to prise or lift off front part of installation frame (in area of switches) from door trim. This will damage switches! Prise or lever installation frame from behind only, as shown by -arrow-. Removing – Use removal wedge -VAS 3409- to carefully prise mounting frame out of door trim -arrow-.

– Disconnect connectors -arrows-.

– Release locking lugs -arrows- and remove the switch module from the installation frame. Installing

Installation is carried out in reverse order of removal.

Removing and installing remote release button for fuel filler flap and rear lid E463-

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Note

The remote release button for fuel filler flap and rear lid -E463has an integrated button illumination bulb -L76- , which cannot be replaced separately.

396

Rep. gr.96 - Lights, bulbs, switches - interior

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3.6

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. ♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape. Removing – Remove door trim ⇒ General body repairs, interior; Rep. gr. 70 . – Disconnect connector -arrow-.

– Release locking lugs -arrows- and remove remote release button for fuel filler flap and rear lid -E463- from door trim pan‐ el. Installing

Installation is carried out in reverse order of removal.

Removing and installing interior moni‐ toring/vehicle inclination deactivation switch

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The interior monitoring deactivation switch -E267- / deactivation button for vehicle inclination sender -E360- are combined in one unit and installed in trim of B-pillar at bottom. AG.

The shape of the switch has been changed from model year 2007 onwards. Special tools and workshop equipment required

3. Lights and switches in front doors and B-pillar

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397

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Removal wedge -VAS 3409-

Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. ♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available n AG. Volkswagen AG do es n masking tape. olkswage o t gu ara nte eo ra c

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– Use removal wedge -VAS 3409- to unclip switch -1- from trim.

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– Disconnect connector -arrow-. Installing

Installation is carried out in reverse order of removal.

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3.8

Removing and installing central locking deadlock function warning lamp -SAFE-K133-

The central locking deadlock function warning lamp -SAFE- K133- is located near to the exterior mirror in the driver's door trim.

398

Rep. gr.96 - Lights, bulbs, switches - interior

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

3.8.1

Removing and installing central locking deadlock function warning lamp -SAFE-K133Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. ♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape. Removing – Remove driver side front door trim ⇒ General body repairs, interior; Rep. gr. 70 . – Unclip central locking deadlock function warning lamp -SAFE-K133- -1- by pressing locking lugs together -arrows- and remove from door trim panel.

Installing

rrectness of i t to the co nform spec a t ion h re wit in t his

Install in the reverse order of removal. When doing this, note the following: Ensure that the central locking deadlock function warning lamp SAFE- -K133- engages properly into door trim.

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– Pull connector -1- off central locking deadlock function warn‐ ing lamp -SAFE- -K133- -2-.

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3. Lights and switches in front doors and B-pillar

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399

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

4

Lights and switches in rear doors

4.1

Components - rear door locks

Rear left door lock (depending on equipment) ♦ Rear left door contact switch -F10♦ Rear left central locking lock unit -F222♦ Rear left door central locking motor, lock -V214♦ Rear left door central locking deadlock function motor -V163Rear right door lock (depending on equipment) ♦ Rear right door contact switch -F11♦ Rear right central locking lock unit -F223♦ Rear right door central locking motor, lock -V215agen AG motor -V164♦ Rear right door central deadlock function . Volkswlocking gen AG

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The procedure for removal and installation of rear left window regulator switch, in door -E52- / rear right window regulator switch, in door -E54- is the same and is therefore described for one only. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. ♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape. Prote cted by c o py rig ht . C op yi

– Remove upper part of handle recess from door handle ⇒ General body repairs, interior; Rep. gr. 70 .

Rep. gr.96 - Lights, bulbs, switches - interior

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AG.

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– Disconnect connector -arrow-.

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Removing and installing rear window regulator switch in door

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4.2

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Release the four locking lugs -arrows- and remove rear left window regulator switch, in door -E52- from installation frame. Installing Installation is carried out in reverse order of removal.

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– When installing, make sure you hear the four locking lugs click into place.

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4. Lights and switches in rear doors

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401

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

5

Lights and switches in luggage com‐ partment

5.1

Removing and installing luggage com‐ partment light -W3-

The luggage compartment light -W3- is located in luggage com‐ partment cover on right side. Special tools and workshop equipment required ♦ Removal wedge -VAS 3409-

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Caution

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♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape.

Downloaded from www.Manualslib.com manuals search engine

AG.

Rep. gr.96 - Lights, bulbs, switches - interior

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402

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– Lever luggage compartment light -W3- -1- out of luggage com‐ partment trim using removal wedge -VAS 3409- -arrow-.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Disconnect connector -arrow-. Renewing bulb:

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Caution

Installing

Installation is carried out in reverse order of removal.

5.2

Removing and installing rear lid lock unit -F256-

The rear lid lock unit -F256- is integrated into the rear lid lock and cannot be renewed individually. If the rear lid lock unit -F256- is found to be defective, the entire rear lid lock must always be renewed. ht rig py Co t.

– Renew tailgate lock ⇒ General body repairs, exterior; Rep. gr. 55 .

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♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over.

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5. Lights and switches in luggage compartment

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403

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

6

Lights and switches in roof trim

6.1

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The following components are built into the front interior light W1- : ♦ Front interior light -W1es, in part or in w l purpos hole ercia , is n m ot com

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♦ Left centre reading light -W39♦ Right centre reading light -W40Components cannot be renewed individually. Complete front in‐ terior light -W1- must be renewed. – Renew front interior light -W1- ⇒ page 404 .

6.1.1

Removing and installing front interior light -W1-

Special tools and workshop equipment required

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♦ Remove the ignition key. ♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape.

404

Rep. gr.96 - Lights, bulbs, switches - interior

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♦ Switch off ignition and all electrical consumers.

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♦ Removal wedge -VAS 3409-

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Removing – Use removal wedge -VAS 3409- to carefully prise trim out of front interior light -W1- -arrows-.

– Remove bolts -arrows-. – Remove front interior light -W1- out of console in moulded headliner.

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– Disconnect connectors -arrows-. Installing

Removing and installing bulb of front in‐ terior light -W1-

Special tools and workshop equipment required ♦ Removal wedge -VAS 3409-

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6.1.2

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6. Lights and switches in roof trim

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405

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. ♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape. Removing – Use removal wedge -VAS 3409- to carefully prise lens out of front interior light -W1- -arrow-.

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– Press contact plate -1- of front interior light -W1- to side -arrow- and remove festoon bulb -2-, together with contact plate, from front interior light -W1- .

– Pull contact plate -arrow- off defective festoon bulb.

Prote cted by

Installation is carried out in reverse order of removal.

6.1.3

Removing and installing centre reading lights

Left centre reading light -W39- / right centre reading light -W40are removed and installed in same way and description is only given for one.

406

Rep. gr.96 - Lights, bulbs, switches - interior

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AG.

Installing

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♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over.

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Caution

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– Fit contact plate onto new festoon bulb (12 V/10 W).

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Removing – Remove front interior light -W1- ⇒ page 404 . – Turn bulb holder -arrows- of left centre reading light -W39- by 90° to the left. – Remove bulb holder together with bulb out of left centre read‐ ing light -W39- .

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– Carefully pull glass-base bulb

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Caution

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– Renew glass-base bulb (12 V/5 W).

♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over. Installing

Installation is carried out in reverse order of removal.

6.2

Front interior light -W1- (with sunroof)

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Components cannot be renewed individually. Complete front in‐ terior light -W1- must be renewed.

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♦ Sunroof switch -E8-

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♦ Right centre reading light -W40-

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♦ Left centre reading light -W39-

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♦ Front interior light -W1-

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The following components are built into the front interior light W1- :

– Renew front interior light -W1- ⇒ page 407 .

6.2.1

Removing and installing front interior light -W1-

Special tools and workshop equipment required

6. Lights and switches in roof trim

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407

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Removal wedge -VAS 3409-

♦

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♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape. Removing

– Use removal wedge -VAS 3409- to carefully prise trim out of front interior light -W1- -arrows-.

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– Remove front interior light -W1- out of console in moulded headliner.

Rep. gr.96 - Lights, bulbs, switches - interior

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AG.

408

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– Remove bolts -arrows-.

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♦ Remove the ignition key.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Disconnect connectors -arrows-. Installing Installation is carried out in reverse order of removal.

6.2.2 Removing

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⇒ page 407 .

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– Disconnect connector -arrow-.

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6.2.3

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– Release locking lugs -arrows- and remove sunroof switch -E8from installation frame.

Removing and installing bulb of front in‐ terior light -W1-

Special tools and workshop equipment required

6. Lights and switches in roof trim

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409

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Removal wedge -VAS 3409-

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Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. ♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape.

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– Press contact plate -1- of front interior light -W1- to side -arrow- and remove festoon bulb -2-, together with contact plate, from front interior light -W1- .

410

Rep. gr.96 - Lights, bulbs, switches - interior

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull contact plate -arrow- off defective festoon bulb. – Fit contact plate onto new festoon bulb (12 V/10 W). Caution

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Installing

6.2.4

Replacing centre reading light

Left centre reading light -W39- / right centre reading light -W40are removed and installed in same way and description is only given for one. Removing

– Remove front interior light -W1- ⇒ page 407 . – Turn bulb holder -arrows- of left centre reading light -W39- by 90° to the left. – Remove bulb holder together with bulb out of left centre read‐ ing light -W39- .

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Installation is carried out in reverse order of removal.

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– Carefully pull glass-base bulb out of bulb holder. – Renew glass-base bulb (12 V/5 W). Caution

♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over. Installing Installation is carried out in reverse order of removal.

6.3

Rear interior light -W45- (vehicles with‐ out anti-theft alarm)

The following components are built into the rear interior light W45- : ♦ Rear interior light -W45♦ Rear left reading light -W11♦ Rear right reading light -W12-

6. Lights and switches in roof trim

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411

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Components cannot be renewed individually. Complete rear in‐ terior light -W45- must be renewed. – Renew rear interior light -W45- ⇒ page 412 .

6.3.1

Removing and installing rear interior light -W45Caution

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♦ Remove the ignition key.

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♦ Switch off ignition and all electrical consumers.

Removing

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♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape.

– Release locking lugs -arrows- and remove trim with lens from rear interior light -W45- .

Prote cted by

412

Rep. gr.96 - Lights, bulbs, switches - interior

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AG.

Installation is carried out in reverse order of removal.

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– Disconnect connector -arrow-.

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– Release locking lugs -arrows- and remove rear interior light W45- from moulded headliner.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

6.3.2

Renewing bulb of rear interior light W45-

Removing – Release locking lugs -arrows- and remove trim with lens from rear interior light -W45- .

– Carefully pull glass-base bulb out of holder -arrows-. – Renew glass-base bulb (12 V/5 W). Caution

♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over. Installing

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6.4

Rear interior light -W45- (vehicles with anti-theft alarm) up to MY2009

The following components are built into the rear interior light W45- : ♦ Rear interior light -W45♦ Rear left reading light -W11♦ Rear right reading light -W12-

♦ Anti-theft alarm ultrasonic sensor -G209-

Components cannot be renewed individually. Complete rear in‐ terior light -W45- must be renewed. Anti-theft alarm ultrasonic sensor -G209- is not allowed to be moved from its preset position. – Renew rear interior light -W45- ⇒ page 414 .

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Installation is carried out in reverse order of

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6. Lights and switches in roof trim

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413

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

6.4.1

Removing and installing rear interior light -W45-

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d nte ir se o eo h t If the rear interior light -W45is removed, the anti-theft alarm u ra a c system must be deactivated ⇒ page 430 (up to MY2009). ss

♦

♦ The anti-theft alarm ultrasonic sensor -G209- must not be

moved from its preset position (up to MY2009).

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Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. ♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape. Removing

– Pull entire trim panel -1- (with lens and reflectors) vertically downwards -arrows- out of rear interior light -W45- .

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414

Rep. gr.96 - Lights, bulbs, switches - interior

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– Press both locking lugs -2- in -direction of arrow A- and remove entire rear interior light -W45- -1- in -direction of arrow B- from moulded headliner.

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Note

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Disconnect connectors -1- and -2-. Installing Installation is carried out in reverse order of removal.

6.4.2

Renewing bulb of rear interior light W45-

Note ♦ The anti-theft alarm system must be deactivated when the rear

interior light -W45- bulbs are replaced ⇒ page 430 (up to MY2009).

♦

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– Switch off ignition and all electrical consumers.

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– Pull entire trim panel -1- (with lens and reflectors) vertically downwards out of rear interior light -W45- .

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♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over.

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Caution

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– Pull glass-base bulb to be removed (12 V/5 W) -1- from bulb holder.

Installing Installation is carried out in reverse order of removal.

6. Lights and switches in roof trim

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415

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

6.5

Removing and installing illuminated vanity mirrors

The procedure for removing and installing front passenger side illuminated vanity mirror -W14- / driver side illuminated vanity mir‐ ror -W20- is the same and is described for one only. Special tools and workshop equipment required ♦ Removal wedge -VAS 3409-

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Caution

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♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

Removing

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♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape.

– Use removal wedge -VAS 3409- to prise front passenger side illuminated vanity mirror -W14- carefully out of roof trim.

Downloaded from www.Manualslib.com manuals search engine

AG.

Rep. gr.96 - Lights, bulbs, switches - interior

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416

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Renewing bulb:

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– Disconnect connector -arrow-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Push contact plate -1- of front passenger side illuminated van‐ ity mirror -W14- in direction of arrow and remove festoon bulb -2- from bulb holder. . Volkswagen AG

gen AG – Renew festoon bulb k(12 swaV/ 5 W).

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Installing

Installation is carried out in reverse order of removal.

6.6

Removing and installing garage door operating unit -E284-

Garage door operating unit -E284- is installed in sun visor on driver side. Sun visor and garage door operating unit -E284- can only be re‐ newed together. Removing

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Installing

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– Remove sun visor on driver side together with garage door operating unit -E284- -1- ⇒ General body repairs, interior; Rep. gr. 68 .

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♦ Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evap‐ orate when the bulb is switched on and cause the glass envelope to cloud over.

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Installation is carried out in reverse order of removal. AG.

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6. Lights and switches in roof trim

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417

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7

Lights and switches in centre console

7.1

Buttons in centre console storage com‐ partment

Buttons in centre console storage compartment (depending on equipment) ♦ TCS and ESP button -E256♦ Shock absorber damping adjustment button -E387♦ Park assist steering button -E581♦ Parking aid button -E266♦ Tyre pressure monitor display button -E492♦ Fuel selection switch (petrol, gas) -E395Note olkswagen AG does not gu ara nte eo ra c

G. V en A The procedure for removal and installation is the same sfor but‐ agall k w l o V tons in the centre console storage compartment and by is therefore ed described for just one button. ris

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7.2

tho au ss

The procedure for removal and installation is the same for all but‐ tons in the centre console storage compartment and is therefore described for just one button ( TCS and ESP button -E256- ). Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

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Downloaded from www.Manualslib.com manuals search engine

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Rep. gr.96 - Lights, bulbs, switches - interior

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418

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♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Removing – Carefully lever gear lever gaiter out of centre console -arrows-.

– Remove bolts -arrows-. – Remove mounting frame together with ashtray out of centre console.

– Disconnect connectors -arrows-.

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t a itte iv du pr r o nl f e ng

– Release locking lugs -arrows- and remove TCS and ESP but‐ ton -E256- from installation frame.

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Installation is carried out in reverse order of removal.

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7. Lights and switches in centre console

419

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7.3

Removing and installing AC/DC con‐ verter with socket WARNING

♦ Capacitors are located in AC/DC converter with socket, 12 V - 230 V -U13- / AC/DC converter with socket, 12 V - 115 V -U27- , and these capacitors can be charged with a re‐ sidual voltage. ♦ There is a danger of an electric shock. ♦ Under no circumstances open housing of AC/DC convert‐ er with socket, 12 V - 230 V -U13- / AC/DC converter with socket, 12 V - 115 V -U27- . Special tools and workshop equipment required ♦ Removal wedge -3409-

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Caution

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♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape. ♦ The connector, wiring and 230 V socket must never be repaired.

– Remove two screws -3- (1.5 Nm). – Remove inner socket unit -4-. Both side brackets -5- must be released for this.

420

Rep. gr.96 - Lights, bulbs, switches - interior

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– Use removal wedge -VAS 3409- to remove socket cover -2-, it is clipped in on both sides of socket.

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– Open folding cover -1-.

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Removal

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♦ The complete unit must be replaced if the connector, wir‐ ing and 230 V socket or the AC/DC converter are defec‐ tive.

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– Unclip connector -1- and pull out plug connector.

7. Lights and switches in centre console

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421

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Release electric socket -4- at locking lugs -arrows- and pull electric socket out. – Remove two screws -2 and 3-. – Pull out converter -1-. Installing Installation is carried out in the reverse sequence.

AG.

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Rep. gr.96 - Lights, bulbs, switches - interior

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422

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

immobiliser

General description

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The vehicle features a fourth-generation

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8

New features of the forth-generation immobiliser:

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♦ It is no longer possible to adapt components of other brands for use in VW vehicles. ♦ The ignition keys are pre-programmed at the manufacturer with a base code. This base code contains a specific manu‐ facturer's code. The keys can be taught into a vehicle only if programmed with the correct manufacturer's mode. Fault detection and fault display

The immobiliser is equipped with self-diagnosis.

For fault finding, use vehicle diagnosis, testing and information system -VAS 5051B- in „Guided fault finding“ mode.

8.1

Removing and installing immobiliser control unit -J362-

AG.

The immobiliser reader coil -D2- is joined to the ignition switch and cannot be renewed individually.

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Renewing dash panel insert ⇒ page 173 .

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The immobiliser control unit -J362- is integrated in the dash panel insert. In the event of failure of immobiliser control unit -J362- , the complete dash panel insert must be renewed.

Removing and installing ignition switch ⇒ page 332 .

8.3

Ignition key

Removing and installing battery of ignition key with remote control ⇒ General body repairs, exterior; Rep. gr. 57 . Removing and installing radio container (transmission unit for re‐ mote control central locking) of ignition key ⇒ General body repairs, exterior; Rep. gr. 57 .

8.3.1

Ignition key - variable code transponder

The variable code transponder in the ignition key cannot be re‐ placed. The ignition key must always be replaced if the variable code transponder is defective. Note ♦ If an ignition key is replaced or a further ignition key is required,

the new ignition key must always be adapted to the immobil‐ iser ⇒ page 424 .

♦ If the radio container (transmission unit for remote controlled

central locking) of the ignition key is also replaced, it must be adapted to the convenience system (up to MY2009) ⇒ page 425 .

8.3.2

Loss of the ignition key

All ignition keys are pre-coded to a specific vehicle in the factory and can only be adapted to this vehicle. The relevant vehicle 8. immobiliser

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423

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 identification number must be specified when re-ordering ignition keys. The new keys must subsequently be adapted to the immo‐ biliser control unit -J362- . Note

Before removing lock set or control units „New identity on renew‐ ing all components“ function must be called up ⇒ page 426 . Adapting ignition key ⇒ page 424 , ⇒ page 425

8.3.3

Adapting ignition keys to the immobiliser

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

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– In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: Up to MY2009 ♦ Body ♦ Electrical system

♦ 01 - On Board Diagnosis capable systems

♦ Electrical system

♦ 01 - On Board Diagnosis capable systems ♦ immobiliser 4C download ♦ Functions ♦ Adapt key

424

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8.3.4

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♦ Functions of convenience system central control unit ♦ Adapt and check key with radio remote control

8.3.5

Checking ignition key with remote con‐ trol (from MY2010)

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

8. immobiliser

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425

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system ♦ 01 - On Board Diagnosis capable systems ♦ Onboard supply control unit ♦ Functions ♦ Check ignition key with remote control

8.3.6

New identity on renewing all compo‐ nents

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

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– In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: Up to MY2009. ♦ Body ♦ Electrical system

♦ 01 - On Board Diagnosis capable systems

♦ Body ♦ Electrical system

♦ 01 - On Board Diagnosis capable systems ♦ immobiliser 4C download ♦ Functions ♦ New identity

426

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From MY2010

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

8.3.7

Online system test

Special tools and workshop equipment required

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The following processes are performed with this test program: ♦ System test for online connection ♦ Check of user authorization

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Up to MY2009. ♦ Body ♦ Electrical system ♦ 01 - On Board Diagnosis capable systems ♦ immobiliser 4A download ♦ Functions ♦ Online system test From MY2010 ♦ Body ♦ Electrical system ♦ 01 - On Board Diagnosis capable systems ♦ immobiliser 4C download ♦ Functions ♦ Online system test

8. immobiliser

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The functions of the anti-theft alarm are integrated into the con‐ venience system central control unit -J393- . From MY2010

The functions of the anti-theft alarm are integrated in the onboard supply control unit -J519- . After renewal of the onboard supply control unit -J519- , the antitheft alarm must be adapted ⇒ page 455 . Fault detection and fault display The anti-theft alarm system is equipped with self-diagnosis.

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Assembly overview Note

The components of the anti-theft alarm (ATA) is dependent on the vehicle equipment.

428

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For fault finding, use vehicle diagnosis, testing and information system -VAS 5051B- in „Guided fault finding“ mode.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 1 - Alarm horn -H12❑ In front right wheel housing ❑ Removing and installing ⇒ page 435 2 - Front passenger door con‐ tact switch -F3❑ In front passenger side central locking lock unit -F221❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 57 .

4 - Interior monitoring deacti‐ vation switch -E267❑ in B-pillar trim on driver side ❑ Removing and installing ⇒ page 397 5 - Driver door contact switch F2❑ In driver side central locking lock unit -F220❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 57 . 6 - Rear lid lock unit -F256❑ Removing and installing ⇒ page 403

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7 - Coding rear left door control unit -J388❑ In rear left door ❑ Removing and installing ⇒ Glazing, window regulator; Rep. gr. 64

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9 - Removing and installing central locking deadlock function warning lamp -SAFE- -K133❑ In driver door trim ❑ Removing and installing ⇒ page 399 10 - Onboard supply control unit -J519❑ In driver's footwell under dash panel ❑ Contains central locking and anti-theft alarm system aerial -R47❑ Removing and installing (up to MY2009) ⇒ page 452 ❑ Removing and installing (from MY2010) ⇒ page 452 11 - Coding rear right door control unit -J389❑ In rear right door 9. Anti-theft alarm (ATA)

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429

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ❑ Removing and installing ⇒ Glazing, window regulator; Rep. gr. 64 12 - Front passenger door control unit -J387❑ In front passenger door ❑ Removing and installing ⇒ Glazing, window regulator; Rep. gr. 64 13 - Contact switch for bonnet -F266❑ In lid lock ❑ Removing and installing ⇒ page 382

9.2

Activating and deactivating anti-theft alarm system

Activating anti-theft alarm: The anti-theft alarm is switched on automatically when the vehicle is locked. The anti-theft alarm is then immediately primed. Note

To stop the anti-theft alarm system triggering an alarm unneces‐ sarily, close all windows and doors before locking vehicle. Deactivating anti-theft alarm: Anti-theft alarm system is deactivated if ♦ vehicle is unlocked using unlock button on remote control ♦ the ignition is switched on ♦ the interior monitoring deactivation switch -E267- has been . Volkswagen AG operated gen AG does swa k Vol by d e ris tho u a ss

Unlock the vehicle mechanically (emergency open): – Unlock the driver door. un le

– Switch on ignition within 15 seconds. Note

If you do not switch on the ignition, the alarm will trigger after 15 seconds.

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When the ignition is switched on, the electronic immobiliser de‐ tects a valid vehicle key and deactivates the anti-theft alarm.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

9.3

Removing and installing ultrasonic sen‐ sor (rear interior light) (up to MY2009)

The anti-theft alarm ultrasonic sensor -G209- , comprising four individual sensors -2-, wiring and a control element on the back of the rear interior light -W45- cannot be replaced individually. The rear interior light -W45- must be replaced complete. Removing and installing rear interior light -W45- (vehicles with anti-theft alarm) ⇒ page 414 .

9.4

Removing and installing ultrasonic sen‐ sor (rear left-hand side of roof) (up to MY2009)

From model year 2007 onwards, vehicle inclination sender G384- and anti-theft alarm ultrasonic sensor -G209- are installed in one unit on rear left side of roof. Special tools and workshop equipment required AG. Volkswagen AG d agen o

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♦ Removal wedge -VAS 3409-

Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

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431

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Removing – Use removal wedge -VAS 3409- to unclip anti-theft alarm ul‐ trasonic sensor -G209- -arrow-. Note

Clip -1- which holds anti-theft alarm ultrasonic sensor -G209- in place has three legs. Press three legs of clip toArelease olkswaanti-theft gen AG en G. V alarm does aganti-theft alarm ultrasonic sensor -G209- , otherwise ultra‐ w s k not l o V gu y sonic sensor -G209- will not comedout. b ar

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– Detach connector -1- from anti-theft alarm ultrasonic sensor G209- . Installing

Installation is carried out in reverse order of removal.

Anti-theft alarm sensor -G578- (from MY2010) Note

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♦ The anti-theft alarm sensor -G578- includes the vehicle incli‐ agen lksw Vo by

nation sender -G384- and the interior monitoring sensor G273- (two sensors).

♦ The anti-theft alarm sensor -G578- cannot be dismantled.

Removing and installing anti-theft alarm sensor -G578-

Special tools and workshop equipment required ♦ Removal wedge -3409-

432

AG.

9.5.1

Rep. gr.96 - Lights, bulbs, switches - interior

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9.5

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– Pull off anti-theft alarm ultrasonic sensor -G209- .

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. ♦ When removing and installing components that are in view (switches, covers, trim), maskeoff agen AGtools ( re‐ . Volkswwhere AGareas doto ag n moval wedge -VAS 3409s nlever ks,wscrewdriver) are used e l ot o V y out those components b using commercially available guar d an e s tee masking tape. hori

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Removing

– Remove front interior light -W1- . ♦ Vehicles with sunroof ⇒ page 407 ♦ Vehicles with no sunroof ⇒ page 404 – Remove screws -arrows A-, release locking lugs -arrows Band remove console from moulded headliner in -direction of arrow C-.

– Detach connector -2- from interior monitor send and receive module 1 -G303- -1-.

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– Release the sensor fasteners and take the sensors and the interior monitor send and receive module 1 -G303- out of the moulded headlining. Installing Installation is carried out in reverse order of removal.

9. Anti-theft alarm (ATA)

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433

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

9.6

Removing and installing vehicle inclina‐ tion sender -G384- (up to 2006)

Vehicle inclination sender -G384- (from 2007) ⇒ page 431 The vehicle inclination sender -G384- -arrow- is located on the right beneath the dash panel, behind the front passenger's airbag. Note

The anti-theft alarm system must be deactivated before vehicle inclination sender -G384- is removed ⇒ page 430 . Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

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– Remove glove compartment ⇒ Rep. gr. 68 .

– Unscrew bolts -1- and remove vehicle inclination sensor G384- from bracket. – Detach connector -2- from vehicle level sender -G384- . Installing

Installation is carried out in reverse order of removal.

Vehicle inclination sender -G384- (from MY2010) Note

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♦ The anti-theft alarm sensor -G578- includes the vehicle incli‐

Removing and installing anti-theft alarm sensor -G578⇒ page 432 .

434

Rep. gr.96 - Lights, bulbs, switches - interior

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♦ The anti-theft alarm sensor -G578- cannot be dismantled.

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nation sender -G384- and the interior monitoring sensor G273- (two sensors).

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Removing

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

9.8

Interior monitoring sensor -G273- (from MY2010) Note

♦ The anti-theft alarm sensor -G578- includes the vehicle incli‐

nation sender -G384- and the interior monitoring sensor G273- (two sensors).

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Removing and ⇒ page 432 .

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Up to MY2009

The central locking and anti-theft alarm system aerial -R47- is routed from the convenience system central control unit -J393- to the A-pillar on left in the main wiring harness. The central locking and anti-theft alarm system aerial -R47- can‐ not be repaired as this would adversely affect the reception quality. In the event of damage, it is necessary to replace the central locking and anti-theft alarm system aerial -R47- . From MY2010

The central locking and anti-theft alarm system aerial -R47- re‐ ceives the signals from the remote control and passes them to the onboard supply control unit -J519- .

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⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐ tions AG.

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Central locking and anti-theft alarm sys‐ tem aerial -R47-

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9.9

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Removing and installing alarm horn H12-

The alarm horn -H12- is located on the right at the A-pillar in the wing. Special tools and workshop equipment required ♦ Drill -VAS 5134-

♦ Twist drill bit ∅ 6 mm 9. Anti-theft alarm (ATA)

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♦ Pop rivet pliers -VAS 5072-

– Use drill -VAS 5134- and a drill bit (∅ 6 mm) to drill out both pop rivets -arrows-.

– Release connector -1- by opening the cover -2- using a small screwdriver and remove the alarm horn -H12- -3- from the wheel housing.

436

Rep. gr.96 - Lights, bulbs, switches - interior

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– Remove front right wheel housing liner ⇒ General body re‐ pairs, interior; Rep. gr. 66 .

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Removing

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The anti-theft alarm must be deactivated before removing the alarm horn -H12- ⇒ page 430 .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove remains of pop rivets -arrow- from body holes. Installing Note

Remove all metal swarf produced by drilling. – Perform necessary corrosion protection measures ⇒ General Information; Body Repairs, General Body Repairs . Note

For reasons of clarity, the alarm horn -H12- is not shown in the following illustration, therefore the connector is shown discon‐ nected. – Guide clip -2- of alarm horn -H12- into aperture in body -1-. – Secure alarm horn -H12- using new pop rivets. – Install front right wheel housing liner ⇒ General body repairs, interior; Rep. gr. 66 . Testing the alarm horn -H12- : The alarm horn -H12- can be checked using final control diagno‐ sis of convenience system central control unit -J393⇒ page 475 .

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9. Anti-theft alarm (ATA)

437

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

10

Horn

10.1

Removing and installing treble horn H2- / bass horn -H7-

The treble horn -H2- / bass horn -H7- are actuated in parallel by the onboard supply control unit -J519- . Treble horn -H2- / bass horn -H7- are installed on the left and right next to the longitudinal members. Treble horn -H2- / bass horn -H7- are installed and removed in same way. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 . – Disconnect connector -arrow-.

Installing

Installation is carried out in reverse order of removal. Note

When installing, position the horn so it is not in contact with ad‐ jacent components. – Tighten bracket bolt on longitudinal member to 20 Nm.

Checking treble horn -H2- / bass horn H7-

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10.2

Treble horn -H2- / bass horn -H7- can be checked in final control diagnosis of onboard supply control unit -J519- ⇒ page 453 .

Rep. gr.96 - Lights, bulbs, switches - interior

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– Remove screw -arrow- and take out treble horn -H2- .

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

97 –

Wiring

1

Vehicle diagnosis, testing and infor‐ mation systems

All the instructions and information for this manual are found in the workshop manual „Electrical System, General Information“. A link to this workshop manual is not possible at present for tech‐ nical reasons. Please select the workshop manual „Electrical System, General Information“ manually in ELSA.

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1. Vehicle diagnosis, testing and information systems

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Removing and installing fuse holder

2.1

Removing and installing fuse holder on left of dash panel

Special tools and workshop equipment required

Caution

♦ When removing and installing components that are in view (switches, covers, trim), mask off areas where tools ( re‐ moval wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape. Removing – Disconnect battery -A- ⇒ page 4 . – Remove storage compartment on driver side ⇒ General body repairs, interior; Rep. gr. 68 .

440

Rep. gr.97 - Wiring

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When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 .

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Electrical system - Edition 07.2010

n AG. Volkswagen AG do es n wage ot g olks V y ua db ran e Jetta 2005 ➤ ir s tee o h t or u ac a ss

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove side cover -1- of dash panel by inserting removal wedge -VAS 3409- in recess -2- and levering off side cover -1- in -direction of arrow-.

– Remove bolts -arrows- and guide out fuse holder -1- towards interior (be careful not to stretch wiring). Installing

Installation is carried out in reverse order of removal.

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– Remove fuse assignment card -1- out of fuse holder -2-.

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2. Removing and installing fuse holder

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441

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

3

Removing and installing relay carrier

3.1

Removing and installing relay carrier on left beneath dash panel Caution n AG. Volkswagen AG do es n wage ot g ua ran tee or ac

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– Disconnect battery -A- ⇒ page 4 .

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– Remove storage compartment on driver side ⇒ General body repairs, interior; Rep. gr. 68 .

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– Unclip locking lugs in direction of -arrow- outwards and then push connectors -1- through relay carrier.

442

Rep. gr.97 - Wiring

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The number of relays depends on the vehicle equipment level.

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– Pull relays -arrows- out of relay carrier.

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– Unscrew bolts -arrows- for bracket.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Release locking lug -1- of relay carrier in direction of -arrowand take out relay carrier. Installing Carry out installation in the reverse sequence, noting the follow‐ ing: – First clip connectors in relay carrier.

– Place relay carrier -2- in guide -1- and clip relay carrier in place.

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3.2

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Removing and installing relay carrier on onboard supply control unit -J519- (up to MY2009) Note

♦ The onboard supply control unit -J519- and the relay carrier

attached to the onboard supply control unit -J519- located on left of dash panel form one unit and cannot be separated.

♦ If the onboard supply control unit -J519- is to be renewed, the

procedure ⇒ page 455 for reading the codes stored in the on‐ board supply control unit -J519- must always be carried out.

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♦ Remove the ignition key.

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♦ Switch off ignition and all electrical consumers.

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Caution

3. Removing and installing relay carrier

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443

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Removing – Remove storage compartment -1- on driver side ⇒ General body repairs, interior; Rep. gr. 68 .

– Push locking catch -1- of relay carrier plug-in connector on onboard supply control unit -J519- in -direction of arrow A-. – Push locking catch -2- of plug-in connector of onboard supply control unit -J519- in direction of -arrow B-. n AG. Volkswagen AG do es n wage ot g olks V ua by d ran ir se tee o The plug-in connector of onboard supply control unit -J519and h t or ac ausupply control unit -J519- can only be of relay carrier on onboard s s

Note

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Note

The number of connectors depends on the vehicle equipment level. – Unclip onboard supply control unit -J519- and of relay carrier on onboard supply control unit -J519- from retainers -arrows C-. – Pull onboard supply control unit -J519- and of relay carrier on onboard supply control unit -J519- downwards and to rear out of holder. Carry out installation in the reverse sequence, noting the follow‐ ing: agen lksw Vo by

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Note

The locking catches cannot be placed in the „CLOSED“ position until all connectors are „fitted“ correctly.

444

Rep. gr.97 - Wiring

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Installing

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– Detach all connectors of onboard supply control unit -J519and of relay carrier on onboard supply control unit -J519- .

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pulled off after the locking catches have been moved to the „OPEN“ position.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

3.3

Removing and installing relay carrier on onboard supply control unit -J519- (from MY2010) Note

The relay carrier on the onboard supply control unit -J519- is clip‐ ped under the onboard supply control unit -J519- and can be removed. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing

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– Remove trim in driver's footwell ⇒ terior; Rep. gr. 68 .

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– Remove left footwell light -W9- ⇒ page 388 .

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Note

The wiring of the left footwell light and of the diagnostic connector can remain connected. – Remove knee airbag in driver's footwell ⇒ General body re‐ pairs, interior; Rep. gr. 69 . – Remove the metal beam above the knee airbag ⇒ General body repairs, interior; Rep. gr. 70 . – Release both locking lugs -arrows- and pull relay carrier -2counter to direction of travel, backwards, out of onboard sup‐ ply control unit -J519- -1-.

Installation is carried out in the reverse sequence.

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– Taking connected wiring length into consideration swing relay carrier downwards and unclip relay.

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3. Removing and installing relay carrier

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445

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

4

Electronics boxes

4.1

Removing and installing electronics box on left side of engine compartment Caution

When battery -A- is disconnected and reconnected, the pro‐ cedure described in the workshop manual must be strictly observed ⇒ page 4 . Removing – Disconnect battery -A- ⇒ page 4 . – Push safety clip -1- in direction of -arrow- and remove cover from electronics box -2- upwards.

– Unclip wiring from cable guides.

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Rep. gr.97 - Wiring

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446

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– Remove wiring from stud connections.

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– Open -arrows- covers -2- of cable guides on electronics box.

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– Remove nuts

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Undo and remove central bolt -arrow- from E-box -1-. Note

Removing the central bolt -arrow- causes the E-box -1- to be pushed upwards off the E-box mounting. – Pull electronics box -1- upwards off bracket of electronics box.

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Note

For removal of the flat contact housing -1-, the air filter housing (on vehicles with diesel engine only), the battery -A- and the bat‐ tery tray must be removed. – If necessary, remove air filter housing. – Remove battery -A- ⇒ page 4 .

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– Remove bolts -arrows- for battery tray -1-.

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– Take battery tray -1- out of vehicle.

4. Electronics boxes

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447

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Press tabs apart on bracket of electronics box -arrows B- and slide flat contact housing -1- sideways -arrow A- out of bracket of electronics box. – Press tabs apart on bracket of electronics box -arrows C- and slide flat contact housing -2- forwards -arrow D- out of bracket of electronics box.

– Remove securing nuts -arrows- from bracket of E-box -1-. Note

The installation of an additional relay carrier depends entirely on the vehicle equipment.

– Pull bracket of electronics box -1- upwards off studs (be careful not to stretch wiring of additional relay carrier). – Unclip additional relay carrier -1- sideways out of bracket of electronics box -2-.

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Installing

Carry out installation in the reverse sequence, noting the follow‐ ing:

448

Rep. gr.97 - Wiring

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AG.

– Tighten threaded connections to specified torques ⇒ page 507 .

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– Take bracket of electronics box -2- out of vehicle.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Mount cover -2- on E-box and push safety clip -1- in direction of -arrow- until cover -2- engages. Note

Then check whether the cover -2- of the electronics box is en‐ gaged correctly.

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4. Electronics boxes

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449

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

5

Control units

5.1

Onboard supply control unit -J519-

General description The onboard supply control unit -J519- and the relay carrier at‐ tached to the onboard supply control unit -J519- located on left of dash panel form one unit and cannot be separated (up to MY2009). The relay carrier on the onboard supply control unit -J519- is clip‐ ped under the onboard supply control unit -J519- and can be removed (from MY2010). Additional information: ⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐ tions ⇒ Operating manual The onboard supply control unit -J519- has the following functions in the vehicle: Up to MY2009 ♦ Electrical load management ♦ Exterior light control ♦ Turn signal control ♦ ♦

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♦ Ambient lighting ♦ Terminal control ♦ Dimmers, instrument lighting ♦ Fuel pump presupply ♦ Alternator stand-by ♦ Horn

From MY2010 ♦ Electrical load management ♦ Exterior light control ♦ Turn signal control ♦ Wipe/wash windscreen and rear window ♦ Headlight washer system cop yri gh t . Co py i

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♦ Dimmers of instrument lighting ♦ Footwell lights ♦ Fuel pump presupply

450

Rep. gr.97 - Wiring

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♦ Terminal control

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♦ Interior light control

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♦ Rain and light sensor

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♦ Interior light control

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Alternator stand-by ♦ Horn ♦ Hazard warning light ♦ Release control ♦ Control of the central locking system ♦ Actuation of the front and rear door control units . Volkswage

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♦ Activation of the immobiliser The following functions can be adapted: Up to MY2009 ♦ Adapting coming home time ⇒ page 461 ♦ Adapting leaving home time ⇒ page 461

♦ Adapting switch-off time of heated rear window ⇒ page 456 ♦ Adapting footwell light dimmer value ⇒ page 463 ♦ Coding/decoding daytime running lights ⇒ page 456 ♦ Setting load management

From MY2010

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♦ Setting „active time“ for headlight washer system ⇒ page 455

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♦ Activation of the entry and start authorisation

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♦ Adapting acoustic feedback when unlocking ⇒ page 457 ♦ Adapting acoustic feedback when locking ⇒ page 458

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♦ Adapting turn signal cycles for lane change flash ⇒ page 458 agen lksw Vo by

♦ Adapting automatic unlocking on removing ignition key ⇒ page 459 AG.

♦ Adapting automatic locking at 15 km/h ⇒ page 460 ♦ Adapting confirmation of convenience closing ⇒ page 460 ♦ Adapting coming home time ⇒ page 461 ♦ Adapting leaving home time ⇒ page 461 ♦ Adapting ATA delay on opening driver door ♦ Adapting unlocking of individual doors ⇒ page 462 ♦ Adapting sensitivity of interior monitoring ♦ Adapting sensitivity of inclination sensor ♦ Deactivating factory mode ⇒ page 463 ♦ Adapting footwell light dimmer value ⇒ page 463 ♦ Adapting convenience operation via remote control ⇒ page 464 ♦ Adapting country setting for intelligent alarm horn ♦ Adapting visual feedback when locking ⇒ page 464 ♦ Adapting remote control unit key ⇒ page 465 5. Control units

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451

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Final control diagnosis ⇒ page 453 . Note ♦ It depends on the fitted optional equipment whether or not the

above-mentioned adaptations can be carried out.

♦ If the onboard supply control unit -J519- is to be renewed, the

procedure ⇒ page 455 for reading the codes stored in the on‐ board supply control unit -J519- must always be carried out.

Fault detection and fault display The on-board supply control unit -J519- is equipped with self-di‐ agnosis. For fault finding, use vehicle diagnosis, testing and information system -VAS 5051B- in „Guided fault finding“ mode.

5.1.1

Removing and installing onboard supply control unit -J519- (up to MY2009)

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The onboard supply control unit -J519- is removed in the same way as is the relay carrier on onboard supply control unit -J519on left of dash panel ⇒ page 443 . Installing

The onboard supply control unit -J519- is installed in the same way as is the relay carrier on onboard supply control unit -J519on left of dash panel ⇒ page 443 .

Removing and installing onboard supply control unit -J519- (from MY2010)

Note

♦ The relay carrier on the onboard supply control unit -J519- is

♦ The following illustrations show removal on a LHD vehicle.

Removal and installation of onboard supply control unit -J519on an RHD vehicle are performed using the corresponding mirror-image procedure.

452

Rep. gr.97 - Wiring

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procedure ⇒ page 455 for reading the codes stored in the on‐ board supply control unit -J519- must always be carried out.

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♦ If the onboard supply control unit -J519- is to be renewed, the

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clipped under the onboard supply control unit -J519- and can be removed.

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5.1.2

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Removing

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If the onboard supply control unit -J519- is to be renewed, the procedure ⇒ page 455 for reading the codes stored in the on‐ board supply control unit -J519- must always be carried out.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Remove relay carrier from onboard supply control unit -J519⇒ page 445 . – Release and disconnect the three connectors. – Press both catches -arrows- and swing onboard supply control n AG. Volkswagen AG do unit -J519- slightly downwards. e wage

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Carry out installation in the reverse sequence, noting the follow‐ ing: – Insert onboard supply control unit -J519- with rear into bracket first and then push it upwards until it engages audibly.

5.1.3

Onboard supply control unit -J519- final control diagnosis

Special tools and workshop equipment required

♦ Vehicle diagnosis, testing and information system -VAS 5051B-

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Note

Whether the components named below can be checked depends on the fitted equipment options. The following components and functions can be checked by the final control diagnosis for the onboard control unit -J519- : ♦ Left sidelight bulb -M1- / right sidelight bulb -M3- / left tail light bulb -M4- / right tail light bulb -M2♦ Left headlight dipped beam bulb -M29- / right headlight dipped beam bulb -M31♦ Left daytime running light bulb -L174- / right daytime running light bulb -L175♦ Left headlight main beam bulb -M30- / right headlight main beam bulb -M32-

5. Control units

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453

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Left dip beam screen motor -V294- / right dip beam screen motor -V295♦ Left fog light bulb -L22- / right fog light bulb -L23♦ Right reversing light bulb -M17- / left reversing light bulb -M16♦ Left brake light bulb -M9- / right brake light bulb -M10- / addi‐ tional brake light bulb -M25♦ Rear left fog light bulb -L46- / rear right fog light bulb -L47♦ Front left turn signal bulb -M5- / rear left turn signal bulb -M6♦ Front right turn signal bulb -M7- / rear right turn signal bulb M8♦ Number plate light -X♦ Dimmed interior light ♦ Instrument lighting of all keys and switches and the dash panel insert

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a ♦ Terminal 30 voltage supply relay -J317ksw Vol

♦ LED heated

♦ Release of sliding/tilting sunroof ♦ Release of seat heating

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♦ Fuel pump relay -J17-

♦ Headlight washer system relay -J39- / headlight washer sys‐ tem pump -V11♦ Windscreen wipers

♦ Wiper module change direction point ♦ Washer pump -V5-

♦ Dual tone horn relay -J4- / treble horn -H2- / bass horn -H7♦ Left cornering light bulb -L148- / right cornering light bulb L149♦ Heated windscreen -Z2-

♦ Luggage compartment lock – Connect vehicle diagnosis, testing and information system VAS 5051B- . agen lksw Vo by

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– In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. AG.

– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system ♦ 01 - On Board Diagnosis capable systems ♦ Onboard supply control unit ♦ Functions ♦ Onboard supply control unit final control diagnosis

454

Rep. gr.97 - Wiring

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♦ LED heated

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

5.1.4

Coding onboard supply control unit J519-

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: n AG. Volkswagen A ♦ Body

♦ Electrical system

♦ Onboard supply control unit ♦ Functions

♦ Code onboard supply control unit online

5.1.5

Adapting headlight washer system (up to MY2009)

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

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Procedure

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The „active time“ of the headlight washer system can be variably adjusted to between 0 and 12.75 seconds. – Connect vehicle diagnosis, testing and information system VAS 5051B- .

5. Control units

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455

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. . Volkswage n AG wage

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♦ Onboard supply control unit ♦ Functions - onboard supply control unit ♦ Adapting headlight washer system

5.1.6

Adapting switch-off time of headlight washer system (up to MY2009)

Special tools and workshop equipment required

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♦ Vehicle diagnosis, testing and information system -VAS 5051B-

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– Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system ♦ 01 - On Board Diagnosis capable systems ♦ Onboard supply control unit ♦ Functions ♦ Adapt switch-off time of heated rear window

5.1.7

Coding/decoding daytime running light (up to MY2009)

Special tools and workshop equipment required

456

Rep. gr.97 - Wiring

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

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5.1.8

Adapting acoustic feedback when un‐ locking

Special tools and workshop equipment required

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⇒ Operating manual

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♦ Functions

Main beam can be switched on or off by the automatic headlight control. Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

5. Control units

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457

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Body ♦ Electrical system Volkswagen AG does not gu ara nte eo ra c

AG. ♦ 01 - On Board Diagnosis capableswsystems agen

♦ Onboard supply ♦ Functions pe rm itte d

un le

♦ Adapt acoustic feedback when unlocking

rrectness of i t to the co n f o r m spec atio h re n in wit

Adapting acoustic feedback when lock‐ ing

es, in part or in w l purpos hole ercia , is n m ot com

5.1.9

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olk yV db control unit e ris ho ut a ss

Special tools and workshop equipment required

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– Connect vehicle diagnosis, testing and information system VAS 5051B- .

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– In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. AG.

– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system ♦ 01 - On Board Diagnosis capable systems ♦ Onboard supply control unit ♦ Functions ♦ Adapting acoustic feedback when locking

5.1.10

Adapting turn signal cycles for lane change flash

Special tools and workshop equipment required

458

Rep. gr.97 - Wiring

Downloaded from www.Manualslib.com manuals search engine

ht rig py Co t.

Procedure

thi sd o cu m en

r te o iva r rp fo

♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

pe rm itte d

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran e tee ris o th or u ac a ss

– Connect vehicle diagnosis, testing and information system VAS 5051B- .

rrectness of i t to the co n f o r mat spec ion h re wit in

es, in part or in w l purpos hole ercia , is n m ot com

Procedure

ility ab y li an pt ce

un le

♦ Vehicle diagnosis, testing and information system -VAS 5051B-

– In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body

♦ Electrical system ♦ 01 - On Board Diagnosis capable systems

♦ Adapt turn signal cycles for lane change flash ng

Adapting automatic unlocking on remov‐ ing ignition key

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Prote cted b y c op yri gh t . Co py i

Special tools and workshop equipment required

ht rig py Co t.

5.1.11

thi sd o cu m en

♦ Functions

r te o iva r rp fo

♦ Onboard supply control unit

AG.

♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system 5. Control units

Downloaded from www.Manualslib.com manuals search engine

459

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ 01 - On Board Diagnosis capable systems ♦ Onboard supply control unit ♦ Functions ♦ Automatic unlocking on removing ignition key

5.1.12

Adapting automatic locking at 15 km/h

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o te itte iva r du p or nl f e ng

rrectness of i t to the co nform spec a t ion h re wit in t his

Procedure

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d nte ir se o eo h t u ra a c ss

– Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body

♦ Electrical system

♦ 01 - On Board Diagnosis capable systems

♦ Adapting automatic locking at 15 km/h

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

460

Rep. gr.97 - Wiring

Downloaded from www.Manualslib.com manuals search engine

AG.

Adapting confirmation of convenience closing

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5.1.13

ht rig py Co t.

♦ Functions

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♦ Onboard supply control unit

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: n AG. Volkswagen A ♦ Body

♦ Electrical

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♦ Onboard supply control unit ♦ Functions

5.1.14

rrectness of i t to the co nform spec a t i h re o n in wit thi s

♦ Adapt confirmation of convenience closing

Adapting coming home time

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

do c um en

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e ng

ility ab y li an pt ce

♦ 01 - On Board Diagnosis capable systems

ht rig py Co t.

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Coming home: duration of lighting time on leaving the vehicle. agen lksw Vo by

The lighting time of the coming home function can be adjusted between 0 and 120 seconds. AG.

Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system ♦ 01 - On Board Diagnosis capable systems ♦ Onboard supply control unit ♦ Functions ♦ Adapt coming home time

5.1.15

Adapting leaving home time

Special tools and workshop equipment required

5. Control units

Downloaded from www.Manualslib.com manuals search engine

461

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

rrectness of i t to the co nform spec a t ion h re wit in t his

Procedure

– Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body

♦ Electrical system

♦ 01 - On Board Diagnosis capable systems ♦ Onboard supply control unit ♦ Functions

♦ Adapt leaving home time

Adapting unlocking of individual doors Prote cted by

♦ Vehicle diagnosis, testing and information system -VAS 5051B-

agen lksw Vo by

cop yri gh t . Co py i

Special tools and workshop equipment required AG.

Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

462

Rep. gr.97 - Wiring

Downloaded from www.Manualslib.com manuals search engine

ht rig py Co t.

5.1.16

do c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t a itte riv du p r o nl f e ng

The lighting time of the leaving home function can be adjusted between 0 and 120 seconds.

ility ab y li an pt ce

Leaving home: duration

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r o eo h t u ra a c ofsslighting time on opening the vehicle.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Body ♦ Electrical system ♦ 01 - On Board Diagnosis capable systems ♦ Onboard supply control. Vunit olkswage n AG wage

♦ Functionsy Volks b ed

ris ♦ Adapt ho unlocking of individual

Deactivating factory mode

Special tools and workshop equipment required

♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure

rrectness of i t to the co nform spec a t ion h re wit in t his

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t a itte riv du p r o nl f e ng

5.1.17

ility ab y li an pt ce

t au ss

n AG d oes not gu ara nte doors eo ra c

do c um en

– Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. ht rig py Co t.

Prote cted by c o py rig ht . C op yi

– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: agen lksw Vo by

AG.

♦ Body

♦ Electrical system ♦ 01 - On Board Diagnosis capable systems ♦ Onboard supply control unit ♦ Functions ♦ Deactivate factory mode

5.1.18

Adapting footwell light dimmer value

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

5. Control units

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463

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 The footwell lighting dimmer can be adjusted at various levels. Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system ♦ 01 - On Board Diagnosis capable systems ♦ Onboard supply control unit ♦ Functions

n AG. Volkswagen AG do es n ot g ua ran tee or ac

age w ♦ Adapting footwell light dimmer value olks yV db

Special tools and workshop equipment required

rrectness of i t to the co nform spec a t i h re o n in wit thi s

♦ Vehicle diagnosis, testing and information system -VAS 5051B-

ility ab y li an pt ce

se riconvenience Adapting operation via re‐ tho u a mote sscontrol

Procedure

– Connect vehicle diagnosis, testing and information system VAS 5051B- . cop yri gh t . Co py i

– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

agen lksw Vo by

AG.

Prote cted by

♦ Body ♦ Electrical system

♦ 01 - On Board Diagnosis capable systems ♦ Onboard supply control unit ♦ Functions ♦ Adapt convenience operation via remote control

5.1.20

Adapting visual feedback when locking

Special tools and workshop equipment required

464

Rep. gr.97 - Wiring

Downloaded from www.Manualslib.com manuals search engine

ht rig py Co t.

– In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

do c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm te o a itte ir v du p or nl f e ng

5.1.19

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure

– Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body

♦ Electrical system

♦ 01 - On Board Diagnosis capable systems ♦ Onboard supply control unit Prote cted by c o py rig ht. C op yi

♦ Visual feedback when locking

Adapting remote control key AG.

Special tools and workshop equipment required

agen lksw Vo by

5.1.21

ht rig py Co t.

♦ Functions

rrectness of i t to the co nform spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o e t itte ir va du p or nl f e g n

ility ab y li an pt ce

n AG. Volkswagen AG do es n wage ot g olks V ua by d ran ir se tee o h t or ac au s s

♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system ♦ 01 - On Board Diagnosis capable systems 5. Control units

Downloaded from www.Manualslib.com manuals search engine

465

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Onboard supply control unit ♦ Functions ♦ Adapt remote

Checking remote control unit key

Special tools and workshop equipment required

♦ Vehicle diagnosis, testing and information system -VAS 5051B-

rrectness of i t to the co nform spec a t ion h re wit in t his

Procedure

ility ab y li an pt ce

– Connect vehicle diagnosis, testing and information system VAS 5051B- . c o p yri gh t. C op yi

– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

agen lksw Vo by

AG.

Prote cted by

♦ Body ♦ Electrical system

♦ 01 - On Board Diagnosis capable systems ♦ Onboard supply control unit ♦ Functions ♦ Check remote control unit key

5.1.23

Coding rain and light sensor -G397-

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- .

466

Rep. gr.97 - Wiring

Downloaded from www.Manualslib.com manuals search engine

ht rig py Co t.

– In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

do c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o te itte iva r du p or nl f e ng

5.1.22

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system ♦ 01 - On Board Diagnosis capable systems ♦ Onboard supply control unit ♦ Functions ♦ Code rain/light sensor

5.1.24

Adapting sensitivity of interior monitor‐ ing system

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm te o a itte ir v du p or nl f e ng

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Procedure

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r o eo h t u ra a c ss

– Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system

Prote cted by

Data bus diagnostic interface -J533-

AG.

5.2

agen lksw Vo by

♦ Adapt sensitivity of interior monitoring

cop yri gh t . Co py i

♦ Functions

ht rig py Co t.

♦ Onboard supply control unit

do c um en

♦ 01 - On Board Diagnosis capable systems

General description The data bus diagnostic interface -J533- is designed as a sepa‐ rate control unit. It is responsible for the following in the vehicle: ♦ Exchange of data between the CAN data bus systems „pow‐ ertrain CAN data bus“, „convenience CAN data bus“ and „infotainment CAN data bus“.

5. Control units

Downloaded from www.Manualslib.com manuals search engine

467

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Conversion of diagnostic data from CAN data bus systems to K lead and visa versa, so that data can be used by vehicle diagnostic, testing and information system -VAS 5051A- . If the data bus diagnostic interface -J533- is to be removed, the procedure ⇒ page 468 must always be performed to read out the codes stored in the unit. Fault detection and fault display The data bus diagnostic interface -J533- is equipped with selfdiagnosis. For fault finding, use vehicle diagnosis, testing and information system -VAS 5051B- in „Guided fault finding“ mode. Additional information: ⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐ tions ⇒ Operating manual

Renewing data bus diagnostic interface -J533-

ility ab y li an pt ce

urposes, in part or in wh ole, cial p is n mer m ot p r co erm o te a itte ir v du p or nl f e ng

5.2.1

n AG. Volkswagen AG do es n wage ot g olks V ua by d ran ir se tee o h t or ac au s s

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Procedure

♦ Electrical system ♦ 01 - On Board Diagnosis capable systems ♦ Data bus diagnostic interface ♦ Data bus diagnostic interface functions ♦ Renewing data bus diagnostic interface

5.2.2

Removing and installing data bus diag‐ nostic interface -J533- (left-hand drive vehicle)

The data bus diagnostic interface -J533- is located in the driver's footwell, on the right, next to the steering column.

468

Rep. gr.97 - Wiring

Downloaded from www.Manualslib.com manuals search engine

AG.

♦ Body

agen lksw Vo by

Prote cted by c o py rig ht. C op yi

– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

ht rig py Co t.

– In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

do c um en

– Connect vehicle diagnosis, testing and information system VAS 5051B- .

un le pe rm itte d

es, in part or in w l purpos hole ercia , is n m ot com

rrectness of i t to the co n f o r m spec atio h re n in wit

Prior to removal of the data bus diagnostic interface -J533- , al‐ ways perform the procedure ⇒ page 468 to read out the codes stored in the unit.

ility ab y li an pt ce

Note

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Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing

– Remove driver's's footwell cover ⇒ General body repairs, in‐ terior; Rep. gr. 68 . r te o iva r rp fo

ng

Installation is carried out in reverse order of removal. AG.

Prote cted by

5.2.3

agen lksw Vo by

cop yri gh t . Co py i

Installing

ht rig py Co t.

– Press securing pins -3- together -arrows- and push out of holes.

thi sd o cu m en

– Release and detach connector -1- from data bus diagnostic interface -J533- -2-.

Removing and installing data bus diag‐ nostic interface -J533- (right-hand drive vehicle)

The data bus diagnostic interface -J533- is located in the driver side footwell, above the relay carrier. Note

Before removing data bus diagnostic interface -J533- , it is es‐ sential that the work procedure ⇒ page 468 for reading out the codes stored in the data bus diagnostic interface -J533- is carried out. Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Remove windscreen wiper system ⇒ page 183 .

5. Control units

Downloaded from www.Manualslib.com manuals search engine

469

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove the three nuts -arrows- and remove cover -1-.

. Volkswagen AG gen AG does not gu y b ara d e nte is Press control unit guides apart slightly on either side and pull r o eo h data bus diagnostic ut interface -J533- upwards out of bracket. ra a c s s

a ksw – Release and disconnect connector -1-. Vol

–

Installation is carried out in reverse order of removal.

rrectness of i t to the co nform spec a t ion h re wit in t his

5.2.4

Coding data bus diagnostic interface J533-

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

agen lksw Vo by

AG.

Prote cted by c o py rig h t . Co py i

– Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system ♦ 01 - On Board Diagnosis capable systems ♦ Data bus diagnostic interface ♦ Data bus diagnostic interface functions

470

Rep. gr.97 - Wiring

Downloaded from www.Manualslib.com manuals search engine

ht rig py Co t.

Procedure

do c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t a itte iv du pr r o nl f e ng

ility ab y li an pt ce

Installing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Code data bus diagnostic interface

5.2.5

Checking bus activity

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

n AG. Volkswagen AG do es n wage ot g olks V y ua db ran e ir s tee o hto see if the individual drive Using this test it is possible to check t or u ac a busses (powertrain, conveniencessand infotainment) have

– Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system

♦ 01 - On Board Diagnosis capable systems ♦ Data bus diagnostic interface

♦ Data bus diagnostic interface functions ♦ Check bus activity

Checking bus participants Prote cted by c o py rig ht . C op yi

Special tools and workshop equipment required

agen lksw Vo by

AG.

♦ Vehicle diagnosis, testing and information system -VAS 5051B-

ht rig py Co t.

5.2.6

rrectness of i t to the co nform spec at i h re o n wit in t his d o cu m en

es, in part or in w l purpos hole ercia , is n m m ot p r co erm o e t a itte v i r du p or nl f e ng

Procedure

ility ab y li an pt ce

changed to the sleep mode.

Using this test it is possible to check the status of the connection from the data bus diagnostic interface -J533- to another bus node.

5. Control units

Downloaded from www.Manualslib.com manuals search engine

471

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ Electrical system ♦ 01 - On Board Diagnosis capable systems ♦ Data bus diagnostic interface ♦ Data bus diagnostic interface functions ♦ Check bus participants

5.3

Convenience system central control unit -J393-

General description The convenience system control unit -J393- is responsible for the following in the vehicle: ♦ Sliding/tilting sunroof control (release instruction) ♦ Power window control (release instruction) ♦ Central locking control ♦ Anti-theft alarm system control ♦ Radio-wave receiver ♦ Rear lid lock ♦ Convenience operation

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swaadapted Some of the above mentioned functions can kbe Vol y b ⇒ page 474 . ed

Fault detection and fault display

ris ho ut a ss

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o te itte iva r du p or nl f e ng

ility ab y li an pt ce

The convenience system central control unit -J393- is equipped with self-diagnosis.

rrectness of i t to the co nform spec a t ion h re wit in t his

For fault finding, use vehicle diagnosis, testing and information system -VAS 5051B- in „Guided fault finding“ mode. Additional information:

♦ ⇒ Operating manual

♦ ⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐ cations

5.3.1

Removing and installing convenience system central control unit -J393Caution

♦ Switch off ignition and all electrical consumers.

AG.

Downloaded from www.Manualslib.com manuals search engine

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

Rep. gr.97 - Wiring

ht rig py Co t.

472

do c um en

♦ Remove the ignition key.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Removing – Remove glove compartment ⇒ General body repairs, interior; Rep. gr. 68 . – Pull locking lug -1- of retainer for convenience system central control unit -J393- in -direction of arrow- and push conven‐ ience system central control unit -J393- until recesses -2- are positioned over recesses -3-.

Note

The connectors can only be released and detached once the re‐ cesses -arrows- of the connector and bracket are aligned with each other precisely. – Detach connectors from central control unit of convenience system -J393- . Note

The number of connectors depends on the vehicle equipment level. – Remove securing nuts -arrows-. G. Volkswagen nA wage

AG do e

s no ks – Remove brackety with t gucontrol unit Vol central convenience system b ara d -J393- . e nt s i

r ho ut a ss

ee or ac

Installing

Carry out installation in the reverse sequence, noting the follow‐ ing:

thi sd o cu m en

ht rig py Co t.

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AG.

Prote cted by

cop yri gh t . Co py i

Downloaded from www.Manualslib.com manuals search engine

rrectness of i t to the co n f o r m spec atio h re n in wit

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm o e t a itte iv du pr r o nl f e ng

ility ab y li an pt ce

– Pull retaining lug -1- in -direction of arrow B- and push central convenience system control unit -J393- -2- in -direction of arrow A- out of bracket.

5. Control units

473

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 The connectors can only be plugged in and locked once the re‐ cesses -arrows- of the connector and bracket are aligned with each other precisely. If a new convenience system central control unit -J393- has been installed, it must be coded ⇒ page 474 .

5.3.2

Coding convenience system central control unit -J393- (up to MY2009)

Special tools and workshop equipment required n AG. ♦ Vehicle diagnosis, testing and information system -VAS wage olks V 5051Bby

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm te o a itte ir v du p or nl f e ng

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Procedure

ility ab y li an pt ce

ss

ed ris ho t au

Volkswagen AG does not gu ara nte eo ra c

– Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

Prote cted by c o py rig ht . C op yi

♦ 01 - On Board Diagnosis capable systems

♦ Code convenience system central control unit

5.3.3

Adapting components - convenience system central control unit -J393- (up to MY2009)

Special tools and workshop equipment required

474

Rep. gr.97 - Wiring

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♦ Functions of convenience system central control unit

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♦ Body

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

The following functions can be adapted: ♦ Activating/deactivating „single door opening“ ♦ Activating/deactivating „automatic locking at speeds greater than 15 km/h“ ♦ Activating/deactivating „automatic unlocking when ignition . Volkswagen AG n AGkey does wage is removed“ no olks

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♦ Activating/deactivating „anti-theft alarm system - alarm delay when driver's door is opened“ ♦ „Sensitivity of tilt angle sensor“ ♦ „Sensitivity of interior monitoring system“ Procedure

– Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

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5.3.4

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– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

Final control diagnosis - convenience system central control unit -J393- (up to MY2009)

Special tools and workshop equipment required

5. Control units

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475

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Procedure

– Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: Prote cted by c o py rig ht . C op yi

♦ General body repairs

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♦ Functions of convenience system central control unit ♦ Final control diagnosis

5.3.5

Reading alarm sources of anti-theft alarm (up to MY2009)

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ General body repairs

476

Rep. gr.97 - Wiring

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♦ Body

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♦ Vehicle 5051B-

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5.4

Driver door control unit -J386-

General description

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The driver door control unit -J386- and the driver side window regulator motor -V147- are contained in one unit and cannot be replaced individually.

If the driver door control unit -J386- or the driver side window reg‐ ulator motor -V147- are replaced, then the work procedure „Cod‐ ing driver door control unit“ must be subsequently performed ⇒ page 477 . Additional information:

⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐ tions ⇒ Operating manual

5.4.1

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Removing and installing driver door con‐ trol unit -J386-

Removing and installing driver door control unit -J386- ⇒ General body repairs, exterior; Rep. gr. 64 . ht rig py Co t.

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Note

If the driver door control unit -J386- or the driver side window reg‐ ulator motor -V147- are replaced, then the work procedure „Cod‐ ing driver door control unit“ must be subsequently performed ⇒ page 477 .

5.4.2

Coding driver door control unit -J386-

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: 5. Control units

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477

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Body ♦ General body repairs ♦ Driver door electronics ♦ Functions of driver door control unit ♦ Code driver door control unit

5.5

Front passenger door control unit -J387-

General description The front passenger door control unit -J387- and the front pas‐ senger side window regulator motor -V148- are contained in one unit and cannot be replaced individually. If the front passenger door control unit -J387- or the front pas‐ senger side window regulator motor -V148- are replaced, then the work procedure „Coding front passenger door control unit“ must be subsequently performed ⇒ page 478 . Additional information: ⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐ tions ⇒ Operating manual

5.5.1

Removing and installing front passenger door control unit -J387-

Removing and installing passenger door control unit -J387- ⇒ General body repairs, exterior; Rep. gr. 64 .

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work procedure „Coding front passenger door control unit“ must be subsequently performed ⇒ page 478 .

Coding front passenger door control unit -J387-

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5.5.2

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Rep. gr.97 - Wiring

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478

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– In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

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– Connect vehicle diagnosis, testing and information system VAS 5051B- .

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Procedure

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ General body repairs ♦ Front passenger door electronics ♦ Functions of front passenger door control unit ♦ Coding front passenger door control unit

5.6

Coding rear left door control unit -J388-

General description The rear left door control unit -J388- and the rear left window reg‐ ulator motor -V26- are contained in one unit and cannot be replaced individually. If the rear left door control unit -J388- or the rear left window reg‐ ulator motor -V26- are replaced, then the work procedure „Coding rear left door control unit“ must be subsequently performed ⇒ page 479 . Additional information:

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Removing and installing rear left door control unit -J388-

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Removing and installing rear left door control unit -J388- ⇒ Gen‐ eral body repairs, exterior; Rep. gr. 64 . Note

If the rear left door control unit -J388- or the rear left window reg‐ ulator motor -V26- are replaced, then the work procedure „Coding rear left door control unit“ must be subsequently performed ⇒ page 479 .

5.6.2

Coding rear left door control unit -J388-

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Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- .

5. Control units

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479

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ General body repairs ♦ Rear left door electronics ♦ Function of rear left door control unit ♦ Coding rear left door control unit

5.7

Coding rear right door control unit -J389-

General description The rear right door control unit -J389- and the rear right window regulator motor -V27- are contained in one unit and cannotebe n AG. Volkswagen AG do es n wag replaced individually. o olks

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Additional information:

⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐ tions ⇒ Operating manual

5.7.1

Removing and installing rear right door control unit -J389-

Removing and installing rear right door control unit -J389- ⇒ General body repairs, exterior; Rep. gr. 64 . Note

Coding rear right door control unit -J389-

480

Rep. gr.97 - Wiring

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♦ Vehicle diagnosis, testing and information system -VAS 5051B-

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If the rear right door control unit -J389- or the rear right window regulator motor -V27- are replaced, then the work procedure „Coding rear right door control unit“ must be subsequently per‐ formed ⇒ page 480 .

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ed right window If the rear right door control unit -J389- or the orear ris hwork procedure t regulator motor -V27- are replaced, then the u s a subsequently per‐ „Coding rear right door control unit“ must sbe formed ⇒ page 480 .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ General body repairs ♦ Rear right door electronics

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♦ Functions of rear right door control unit ♦ Coding rear right door control

Trailer detector control unit -J345-

The trailer detector control unit -J345- -arrow- is located behind the left luggage compartment side panel trim. Up to MY2009.

From MY2010 General description

Check trailer detector control unit -J345- using socket tester V.A.G 1537/A- .

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The trailer detector control unit -J345- is supplied with information (light control) from the onboard supply control unit -J519- and convenience system central control unit -J393- via the CAN data bus.

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The trailer detector control unit -J345- detects „trailer operation“ from a power draw of minimum 5 W and transmits this information to various control units via the CAN data bus. „Trailer operation“ can only be detected if at least turn signal indicators or side mark‐ er lights are switched on.

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5.8

Fault detection and fault display The trailer detector control unit -J345- is equipped with self-diag‐ nosis. For fault finding, use vehicle diagnosis, testing and information system -VAS 5051B- in „Guided fault finding“ mode. Additional information: ♦ ⇒ Operating manual ♦ ⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐ cations

5. Control units

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481

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

5.8.1

Removing and installing trailer detector control unit -J345- (up to MY2009)

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1783-

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♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key.

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Removing

– Remove left luggage compartment side trim panel ⇒ General body repairs, interior; Rep. gr. 70 . – Detach connectors -2-. Note

The number of connectors at the trailer detector control unit J345- may differ from the illustration, depending on vehicle equip‐ ment. – Remove bolts -1- and take trailer detector control unit -J345together with bracket out of vehicle. cop yri gh t . Co py i

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Installing

Carry out installation in the reverse sequence, noting the follow‐ ing: – Tighten threaded connections to specified torques ⇒ page 507 . Following installation, a new trailer detector control unit -J345must be encoded ⇒ page 483 .

482

Rep. gr.97 - Wiring

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– Remove bolts -arrows- and detach trailer detector control unit -J345- from bracket.

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Caution

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

5.8.2

Removing and installing trailer detector control unit -J345- (from MY2010) Caution

♦ Switch off ignition and all electrical consumers. ♦ Remove the ignition key. Removing – Remove left luggage compartment side trim panel ⇒ General body repairs, interior; Rep. gr. 70 . – Undo bolts -1- and -2- and take trailer detector control unit J345- -4- off plate. – Disconnect the connectors -3- for the trailer detector control unit -J345- -4-. Installing Carry out installation in the reverse sequence, noting the follow‐ ing: . Volkswagen AG gen AG d

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Coding trailer detector control unit J345- (up to MY2009)

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Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure

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– In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

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– Connect vehicle diagnosis, testing and information system VAS 5051B- .

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5.8.3

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– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ General body repairs ♦ 01 - On Board Diagnosis capable systems ♦ Trailer detector

5. Control units

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483

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Functions ♦ Trailer detector control unit -J345-

Coding trailer detector control unit J345- (from MY2010)

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5.8.4

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Special tools and workshop equipment required

♦ Vehicle diagnosis, testing and information system -VAS 5051B-

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Procedure

♦ General body repairs ♦ Trailer detector ♦ Functions ♦ Code trailer detector control unit

5.8.5

Adapting software - trailer detector con‐ trol unit -J345- (from MY2010)

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

This test programme provides support when renewing or retrofit‐ ting immobiliser control unit.

484

Rep. gr.97 - Wiring

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AG.

♦ Body

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– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

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– In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

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– Connect vehicle diagnosis, testing and information system VAS 5051B- .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession: ♦ Body ♦ General body repairs

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♦ Functions

urposes, in part or in wh ole, cial p is n mer m ot p o c r erm te o a itte ir v du p or nl f e ng

♦ Trailer detector

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♦ Adapt immobiliser control unit software

Trailer detector control unit -J345- final control diagnosis

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5.8.6

Special tools and workshop equipment required

♦ Vehicle diagnosis, testing and information system -VAS 5051B-

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♦ Socket tester -V.A.G 1537/A-

♦ Trailer socket tester -VAS 5800-

5. Control units

Downloaded from www.Manualslib.com manuals search engine

485

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 The trailer detector control unit -J345- only detects „trailer oper‐ ation“ as of a power draw of at least 5 W. The socket tester -V.A.G 1537/A- will become too warm after some minutes of use and will switch itself off. The socket tester V.A.G 1537/A- will function again without problem after it has cooled down. Procedure

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♦ General body repairs

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♦ Body

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– Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

♦ 01 - On Board Diagnostic capable systems (up to MY2009) ♦ Trailer detector ♦ Functions

♦ Trailer detector control unit - final control diagnosis

5.9.1

Removing and installing garage door operation control unit -J530-

– Removing and installing garage door operation control unit J530- ⇒ page 417 .

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051B-

Procedure – Connect vehicle diagnosis, testing and information system VAS 5051B- . – In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“. – Using GoTo button, select „Functions/component“ and the fol‐ lowing menu options in succession:

486

Rep. gr.97 - Wiring

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Checking garage door operating unit E284- (up to MY2009)

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5.9.2

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Garage door operation control unit J530-

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5.9

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Body

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♦ Electrical system

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♦

♦ Switch button

♦ Garage door operating unit

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5. Control units

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487

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

6

Wiring harness and connector re‐ pairs

All the instructions and information for this manual are found in the workshop manual „Electrical System, General Information“. A link to this workshop manual is not possible at present for tech‐ nical reasons. Please select the workshop manual „Electrical System, General Information“ manually in ELSA.

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Rep. gr.97 - Wiring

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488

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Removing and installing engine wir‐ ing harness

⇒ page 489 ⇒ page 490 ⇒ page 491 ⇒ page 497

7.1

Operation and safety notes

Note

Before beginning renewal of a wiring harness, first rectify the cause of the damage (sharp edges on a body part, defective con‐ sumer, corrosion).

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Caution

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– When performing installation work on engine wiring harness, observe the following:

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7

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♦ The procedure described in the workshop manual must be strictly observed when disconnecting and reconnecting the battery -A- . ♦ If a wire or a glow plug connector is damaged, the com‐ plete wiring harness including connector will have to be renewed (connectors cannot be renewed separately).

DANGER!

♦ Follow safety precautions when working on the diesel in‐ jection system ⇒ 4-cyl. diesel engine (2.0 l engine, com‐ mon rail); Rep. gr. 23 . ♦ Note rules on cleanliness ⇒ 4-cyl. diesel engine (2.0 l en‐ gine, common rail); Rep. gr. 23 . These instructions must always be complied with before and during work!

WARNING

Please note the following points during all assembly work, in particular in the engine compartment, due to the narrow instal‐ lation conditions: ♦ Lines of all kinds (fuel, hydraulic fluid, activated charcoal container system, coolant and refrigerant, brake fluid, vac‐ uum) and electric cables must be routed so as to restore original line/cable routing. ♦ Make sure there is adequate clearance from all moving or hot components.

7. Removing and installing engine wiring harness

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489

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7.2

Installation notes Note

♦ Additional information on interfaces and connectors for indi‐

vidual components:

♦ ⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐

cations

Engine control unit -J623- connector installation notes Note

Illustration shows 154-pin plug connection. AEngine control unit -J623- , 154-pin B - 94-pin connector

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Rep. gr.97 - Wiring

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490

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C - 60-pin connector

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Installation note on heat insulation: – Push heat insulation -1- in direction of arrow -A- onto compo‐ nent -3-. – Lock pushbutton -2- in direction of arrow -B-.

Illustration shows correct seating of heat insulation -1- on com‐ ponent -2-.

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♦ Assembly overview - engine wiring harness, intake side ⇒ page 496

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♦ Assembly overview - engine wiring harness, exhaust side ⇒ page 495

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7. Removing and installing engine wiring harness

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491

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7.3.1

Assembly overview - engine wiring harness, top view

1 - Injector connectors, 2-pin 2 - Heat insulation ❑ Note installation posi‐ tion ⇒ page 491 ❑ Renew if damaged. 3 - Position sender for charge pressure positioner -G581connector, 3-pin ❑ Note ⇒ 4-cyl. diesel en‐ gine (2.0 l engine, com‐ mon rail); Rep. gr. 21 4 - Bracket to cylinder head ❑ For wiring harness 5 - Connector fuel pressure regulating valve -N276- , 2-pin ❑ Note ⇒ 4-cyl. diesel en‐ gine (2.0 l engine, com‐ mon rail); Rep. gr. 23 6 - Fuel temperature sender G81- connector, 2-pin ❑ Note ⇒ 4-cyl. diesel en‐ gine (2.0 l engine, com‐ mon rail); Rep. gr. 23

AG. Volkswagen AG d agen oes ksw not l o V gu 7 - Fuel metering valve -N290by ara d e nte s i r connector, 2-pin o eo h t u ra ❑ Note ⇒ 4-cyl.sdiesel en‐ c sa

8 - Glow plug connectors ❑ Note ⇒ 4-cyl. diesel en‐ gine (2.0 l engine, com‐ mon rail); Rep. gr. 28 Caution

Connector ♦ is surrounded by a protective sleeve, if damaged then protective sleeve can be renewed. It♦is essential to comply with working sequence »Removing and installing glow plug connectors« ⇒ page 492 !

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gine (2.0 l engine, com‐ mon rail); Rep. gr. 23

9 - Fuel pressure sender -G247- connector, 3-pin ❑ Notes ⇒ 4-cyl. diesel engine (2.0 l engine, common rail); Rep. gr. 23

Rep. gr.97 - Wiring

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492

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Special tools and workshop equipment required

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Removing and installing glow plug connectors

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 ♦ Pliers -3314-

Removing Caution

– Position pliers -3314- with groove in pliers -arrow A- on top collar of connector -arrow B- and press together slightly. Caution

Position pliers -3314- so that cables are not touched or dam‐ aged. Only use illustrated tool.

Other, unsuitable tools can damage connector. If the connector is damaged upon disconnection, the complete wiring harness including the connector must be replaced. The connector cannot be renewed individually. – Using pliers -3314- , carefully pull connector off glow plug in -direction of arrow-.

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Cable of connector is not allowed to be damaged under any circumstances.

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Do not jerk connector.

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Do not press pliers -3314- together too firmly, otherwise con‐ nector will be damaged. Connector is surrounded by a protective sleeve, if damaged then protective sleeve can be renewed. Installing

7. Removing and installing engine wiring harness

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493

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Guide middle contact of connector -arrow A- by hand into socket of glow plug -arrow B-.

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– Push glow plug connector -1- on by hand until it can be felt to engage.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7.3.2

Assembly overview - engine wiring harness, exhaust side

1 - Connector exhaust gas re‐ circulation temperature sensor -G98❑ Note ⇒ 4-cyl. diesel en‐ gine (2.0 l engine, com‐ mon rail); Rep. gr. 26 2 - Exhaust gas pressure sen‐ sor 2 -G451- connector, 3-pin ❑ Note installation posi‐ tion ❑ Note ⇒ 4-cyl. diesel en‐ gine (2.0 l engine, com‐ mon rail); Rep. gr. 21 . Volkswagen AG

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4 - Connector exhaust gas re‐ circulation valve 2 -N213❑ Note ⇒ 4-cyl. diesel en‐ gine (2.0 l engine, com‐ mon rail); Rep. gr. 21 5 - Cable tie on control line ❑ Note ⇒ 4-cyl. diesel en‐ gine (2.0 l engine, com‐ mon rail); Rep. gr. 26 ❑ Note installation posi‐ tion ❑ Renew 6 - Exhaust gas recirculation temperature sensor -G98❑ Note ⇒ 4-cyl. diesel en‐ gine (2.0 l engine, com‐ mon rail); Rep. gr. 26

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7 - Coolant temperature sender -G62- , 2-pin ❑ Note ⇒ 4-cyl. diesel engine (2.0 l engine, common rail); Rep. gr. 15 ht rig py Co t.

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495

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7.3.3

Assembly overview - engine wiring harness, intake side

1 - Intake manifold flap motor V157- connector, 5-pin ❑ Note ⇒ 4-cyl. diesel en‐ gine (2.0 l engine, com‐ mon rail); Rep. gr. 23 2 - Throttle valve module J338- connector, 50-pin ❑ Note ⇒ 4-cyl. diesel en‐ gine (2.0 l engine, com‐ mon rail); Rep. gr. 23 3 - Insertion foot ❑ Note installation posi‐ tion 4 - Oil pressure switch -F1connector, 1-pin ❑ Note ⇒ 4-cyl. diesel en‐ gine (2.0 l engine, com‐ mon rail); Rep. gr. 17

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5 - Bracket on oil filter bracket ❑ For wiring harness ❑ Note installation posi‐ tion

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6 - Engine speed sender -G28connector, 3-pin ❑ Note ⇒ 4-cyl. diesel en‐ gine (2.0 l engine, com‐ mon rail); Rep. gr. 13 7 - Hall sender -G40- connec‐ tor, 3-pin ❑ Note ⇒ 4-cyl. diesel en‐ gine (2.0 l engine, com‐ mon rail); Rep. gr. 15 8 - Engine speed sender -G28bracket on cylinder head ❑ For wiring harness

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496

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9 - Mechanical exhaust gas recirculation valve -N18- connector, 6-pin ❑ Note ⇒ 4-cyl. diesel engine (2.0 l engine, common rail); Rep. gr. 23

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

7.4

Removing and installing engine wiring harness, 2.0 l, TDI/CR engine (EC/ CBEA)

Special tools and workshop equipment required ♦ Hose clamp up to Ø 25 mm -3094♦ Torque wrench -V.A.G 1331♦ Drip tray -VAS 6208♦ Spring-type clip pliers -VAS 6362-

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Procedure

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Engine must be cold.

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Conditions

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– Before removal, interrogate error memory of all control units ⇒ Vehicle diagnostic, testing and information system VAS 5051 „Vehicle self-diagnosis“. – Remove engine cover ⇒ 4-cyl. diesel engine (2.0 l engine, common rail); Rep. gr. 15 . Caution

Risk of irreparable damage to electronic components when disconnecting battery -A- : ♦ Comply with precautions when disconnecting battery -A- .

7. Removing and installing engine wiring harness

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497

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Disconnect earth cable -arrow- from battery -A- when ignition is switched off. – Remove air filter housing ⇒ 4-cyl. diesel engine (2.0 l engine, common rail); Rep. gr. 23 .

– Remove battery -A- and battery tray -arrows-. – Remove windscreen wiper arms and plenum chamber cover ⇒ page 183 . – Remove bulkhead of plenum chamber.

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The following figure shows the wiring harness viewed from the windscreen with bonnet open. 1-

Bulkhead of plenum chamber

2-

Wiring harness

3-

Windscreen

– Unclip wiring harness -2- from attachments -arrows-.

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– Remove engine control unit -J623- ⇒ 4-cyl. diesel engine (2.0 l engine, common rail); Rep. gr. 23 .

498

Rep. gr.97 - Wiring

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– Remove bulkhead of plenum chamber -3- upwards from ve‐ hicle.

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– Remove bolt -1- and nut -2- from bulkhead of plenum chamber -3-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull off connector -arrow B- on engine control unit -J623-arrow A-.

– Unlock feed-through for wiring harness -A- and retaining lug -arrow-. – Pull off feed-through for wiring harness -A- upwards.

– Pull wiring harness out of bracket -arrow A-. – Unclip cable guide in vicinity of gearbox mounting -arrows B to D-.

– Open cable tie of 14-pin connector, black, coupling point 1 in engine compartment, left -arrow B- and remove connector from bracket. – Disconnect 14-pin connector, black, coupling point 1 in engine compartment, left -arrow A-. ht rig py Co t.

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– Unclip cable guide -arrow C-.

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7. Removing and installing engine wiring harness

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499

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Pull 10-pin connector near left headlight -arrow A- out of brack‐ et -arrow B- and disconnect connector.

– Unlock insertion foot of wiring harness on starter bracket -B-arrow B-. – Unlock insertion foot of wiring harness on oil filter bracket -arrow A-. Location ⇒ Item 3 (page 496) . – Carefully pull wiring harness off brackets.

– Unlock retaining clip of wiring harness and pull off from oil filter bracket -arrow-.

– Pull off connector from mechanical exhaust gas recirculation valve -N18- -1- and from throttle valve module -J338- -2-. Location throttle valve module -J338- ⇒ Item 2 (page 496)

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Rep. gr.97 - Wiring

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

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–

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– Unlock connector from Hall sender -G40- and disconnect -arrow-. Location ⇒ Item 7 (page 496) .

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– Pull off connector from fuel temperature sender -G81- -1- and from fuel metering valve -N290- on high-pressure fuel pump -2-. AG.

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Installation position fuel metering valve -N290⇒ Item 7 (page 492) . – Note the cable routing. – Slide wiring harness out.

– Unlock connector from oil pressure switch -F1- and detach -arrow A-. Location ⇒ Item 4 (page 496) . Note

To unlock and disconnect plug connection from engine speed sender -G28- , it is necessary to remove and install oil filter brack‐ et. – Removing and installing oil filter bracket ⇒ 4-cyl. diesel engine (2.0 l engine, common rail); Rep. gr. 17 .

7. Removing and installing engine wiring harness

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501

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– Detach connector from intake manifold flap motor -V157-arrow A-. Installation location intake manifold flap motor -V157⇒ Item 1 (page 496)

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– Pull cable guide off rail element (high-pressure accumulator) -arrow C-.

– Pull off connector from fuel pressure regulating valve -N276-arrow A-. Location ⇒ Item 5 (page 492) .

502

Rep. gr.97 - Wiring

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– Remove nut from fuel line -arrow D-.

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– Unclip wiring harness from bracket -arrow B-.

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– Pull off connector from fuel pressure sender -G247-arrow A-.

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– Pull wiring harness out of bracket -arrow B-.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Disconnect connector of all injectors -A-. Installation position of injectors ⇒ Item 1 (page 492) – Loosen spring-type clip -arrow B- with spring-type clip pliers VAS 6362- and pull line off rail element (high-pressure accu‐ mulator). – Pull off line -arrow C-. – Prior to removal, clean return line connection on injectors (us‐ ing commercially available cold cleaning agents). – Dry the return line connections. – Pull connectors off all glow plugs. AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r It is essential to comply with working sequence »Removing and eo ho t u ra installing glow plug connectors« ⇒ page 492 ! s a c s

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Installation location of connectors from glow plugs ⇒ Item 8 (page 492)

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– Pull wiring harness with cable guide off rail element and slide out wiring harness. – Pull connector -arrow- off coolant temperature sender -G62- .

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– Slide out cable -arrows-.

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Location ⇒ Item 7 (page 495) .

7. Removing and installing engine wiring harness

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503

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 Illustration shows wiring harness for coolant temperature sender -G62- -arrow-.

-Arrow C- shows wiring harness to following components: ♦ Exhaust gas pressure sensor 2 -G451♦ Position sender for charge pressure positioner -G581♦ Exhaust gas recirculation valve 2 -N213-

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-Arrow D- wiring harness from „bracket on cylinder head cover“. ⇒ page 504 -Arrow A- wiring harness to exhaust gas recirculation temperature sensor -G98- . -Arrow B- wiring harness to exhaust gas recirculation valve 2 N213-Arrow C- bracket for exhaust gas recirculation valve 2 -N213cable.

– Clip on heat insulation -arrows- and pull off connector from exhaust gas pressure sensor 2 -G451- -1-. Installation position ⇒ Item 2 (page 495)

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504

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– Slide out wiring harness from

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Clip on heat insulation -arrow-. Installation position ⇒ Item 3 (page 492)

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– Pull off connector from position sender for charge pressure positioner -G581- -arrow- on pressure socket from turbocharg‐ er and slide cable out of brackets.

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– Pull off connector from exhaust gas recirculation temperature sensor -G98- -arrow A- and slide out cable.

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Installation position of connector exhaust gas recirculation tem‐ perature sensor -G98- ⇒ Item 1 (page 495)

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7. Removing and installing engine wiring harness

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010 – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 . •

Installation view shows vehicle from underneath: Note

Note installation position of cable routing and heat insulation! Installation position exhaust gas recirculation valve 2 -N213⇒ Item 4 (page 495)

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– Remove intake hose ⇒ 4-cyl. diesel engine (2.0 l engine, common rail); Rep. gr. 23 .

Note installation position of cable routing before you slide out ca‐ ble! – Slide cable -1- out carefully between induction hood of turbo‐ charger -2- and preheating hose -3- -arrow A-.

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Carry out installation in the reverse sequence, noting the follow‐ ing:

Ensure all connectors are fitted securely. Attach heat insulation mats in original installation position ⇒ page 491 . Always renew self-locking nuts, seals and securing clips. Hose connections are secured with spring-type clips. It is recommended that spring-type clips should be installed using spring-type clip pliers -VAS 6362- or hose clamp pliers VAS 6340- . Observe notes ⇒ page 490 .

506

Rep. gr.97 - Wiring

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It is essential to comply with working sequence »Removing and installing glow plug connectors« ⇒ page 492 !

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– Carefully remove entire wiring harness for engine from engine compartment.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ Electrical system - Edition 07.2010

8

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Specified torques for wires, lines and cables

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Threaded connections

Specified torques

Nuts -1Nuts -1-

4 Nm 6 Nm

Specified torques for trailer detector control unit -J345-

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Specified torques for E-box on left side of engine compartment

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Specified torques 2 Nm 2 Nm

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8. Specified torques for wires, lines and cables

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507