Electrical System PDF

Service
Workshop Manual
Jetta 2005
Bora 2006
Electrical System
Edition 05.2005
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
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27 - Starter, current supply, CC
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90 - Instruments, GCI
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92 - Windscreen wash/wipe system
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96 - Lights, lamps, switches - inside
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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 MEX5R005820

Jetta 2005 , Bora 2006
Electrical System - Edition 05.2005
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27 - Starter,ut current supply, CC . . . . . . . . . . . . . o.r a. ........................... 1
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1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Fundamentals for batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Types of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.3 Warning notices and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1.4 Battery terminal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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2 Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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2.1 Procedure when checking the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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2.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Checking battery with magic eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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2.4 Checking low maintenance battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Check no load voltage of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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2.6 Battery tester with printer VAS 5097 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.7 Evaluating test result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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3 Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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3.1 Battery charger VAS 5095 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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3.2 Battery charger VAS 5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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3.3 Totally discharged batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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Disconnecting and reconnecting batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.1 Disconnecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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4.2 Connecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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5 Removing and installing battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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5.1 Models with a petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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5.2 Models with a diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6 Torque settings: battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1 Checking starter B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.2 Removing and installing starter, automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.3 Removing and installing starter, automated shift gearboxes . . . . . . . . . . . . . . . . . . . . . . . . 58
7.4 Removing and installing starter, manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8 Torque settings: starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
9.1 Fastening B+ wire to alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
9.2 Checking ribbed belt (poly V-belt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
9.3 Check alternator C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
9.4 Alternator, 1.6 l injection engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
9.5 Alternator, 1.6 l FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9.6 Alternator, 2.0 l FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
9.7 Alternator, 2.0 l FSI turbo engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
9.8 Alternator 2.5 l injection engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
9.9 Alternator, 1.9 l TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
9.10 Alternator, 2,0 l TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
9.11 Removing and installing ribbed belt (poly V-belt) pulley on alternator . . . . . . . . . . . . . . . . 137
9.12 Voltage regulator for alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
10 Torque settings: alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
10.1 General torque settings for all vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
10.2 1.6 l injection engine and 2.0 l FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
10.3 2.0 l FSI turbo engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
10.4 1.9 l and 2.0 l TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
10.5 2.5 l injection engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
11 Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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11.1 Activating and deactivating cruise control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
90 - Instruments, GCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

1 Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.1 Renewing dash panel ainsert
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1.4 Warnings aulamp symbols in dash panel insert . . . . . . . . . r.ac. . . . . . . . . . . . . . . . . . . . . . . . . .
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2 Service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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2.1 Resetting service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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1 Windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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1.1 Deactivating APP function of wiper motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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1.2 Removing and installing the windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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1.3 Removing and installing wiper arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.4 Adjusting wiper blade park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.5 Removing and installing aerodynamic wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
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1.6 Removing and installing rain and light detector sensor G397 . . . . . . . . . . . . . . . . . . . . . . 163
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2 Windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

2.1 Assembly overview of windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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2.2 Removing and installing reservoir for windscreen and headlight washer systems . . . . . . 166
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2.3 Removing and installing washer pump V5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
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2.4 Removing and installing windscreen washer spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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2.5 Adjusting front windscreen washer system spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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3 Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

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3.1 Assembly overview - headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

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3.2 Removing and installing headlight washer system pump V11 . . . . . . . . . . . . . . . . . . . . . . 171
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3.3 Removing and installing pop-up spray jet cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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3.4 Removing and installing spray jet assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
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3.5 Adjusting headlight washer system jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.6 Bleeding the headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4 Wash water line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.1 Windscreen and rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.2 Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
5 Hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.2 Repairing smooth pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.3 Repairing corrugated pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
6 Torque settings: Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
94 - Lights, lamps, switches - outside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

1 Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.1 Assembly overview, Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.2 Removing and installing headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.3 Adjusting headlight installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.4 Renewing headlight bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1.5 Servicing headlight securing lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
1.6 Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2 Main headlights with gas discharge bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.1 Assembly overview - gas discharge headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
2.2 Removing and installing headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.3 Adjusting headlight installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.4 Renewing headlight bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.5 Removing and installing headlight range control motor . . . . . . . . . . . . . . . . . . . . . . . . . . 198
ii Contents
2.6 Removing and installing gas discharge light control unit . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2.7 Headlight range control unit J431 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2.8 Vehicle level sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.9 Servicing headlight securing lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
2.10 Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3 Fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3.1 Assembly overview - fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3.2 Removing and installing fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3.3 Removing and installing fog light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
3.4 Adjusting fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4 Removing and installing sideAmarker . Volkswinagfront
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4.1 Removing and installing Vol
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5 Mirror turn signal db ar
rise bulb and entry light in exterior mirror an.te. . . . . . . . . . . . . . . . . . . . . . . . . . . 209
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5.1 Removing aandut
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5.2 Removings and installing entry light in exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
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6 Tail lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
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6.1 Assembly overview - tail light in side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
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6.2 Removing and installing tail light in side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
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6.3 Removing and installing tail light bulb carrier in side panel . . . . . . . . . . . . . . . . . . . . . . . . 213
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6.4 Assembly overview - tail light in tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
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6.5 Removing and installing tail light in tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
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6.6 Removing and installing tail light bulb carrier in tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
7 Number plate lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
7.1 Removing and installing number plate light X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
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8 Additional brake light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
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8.1 Removing and installing high level brake light bulb M25 . . . . . . . . . . . . . . . . . . . . . . . . . . 218
9 Steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
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9.1 Assembly overview - steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

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9.2 Removing and installing steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

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9.3 Steering column electronics control unit J527 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

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9.4 Steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

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10 Ignition switch and lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

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10.1 Removing and installing steering lock housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

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10.2 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
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10.3 Removing and installing ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
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11 Parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
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11.1 Assembly overview - parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
11.2 Removing and installing parking aid control unit J446 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
11.3 Removing and installing parking aid sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
11.4 Removing and installing rear parking aid warning buzzer H15 . . . . . . . . . . . . . . . . . . . . . . 236
11.5 Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
12 Torque settings: lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
12.1 Torque settings: headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
12.2 Torque settings: fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
12.3 Torque settings - tail light in side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
12.4 Torque settings - tail light in tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
12.5 Torque settings: vehicle level sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
96 - Lights, lamps, switches - inside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

1 Lights and switches in engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.1 Removing and installing bonnet contact switch F266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
2 Lights and switches in dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
2.1 Removing and installing light switch E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
2.2 Removing and installing glove compartment light W6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Contents iii
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2.3 Removing and installing glove compartment light switch E26 . . . . . . . . . . . . . . . . . . . . . . 242
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2.4 Removing and installing switches and instruments illumination regulator E20 . . . . . . . . . . 242
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2.5 Removing and installing front passenger side airbag deactivated warning lamp K145 . . 243
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2.6 Removing and installing hazard warning light switch E3 . . . . . . . . . . . . . . . . . . . . . . . . . . 244
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2.7 Removing and installing left footwell light W9 and right footwell light W10 . . . . . . . . . . . . 244
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2.8 Removing and installing key operated switch to deactivate front passenger side airbag E224
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...................................................................... 246
3 Lights and switches in front doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
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3.1 Removing and installing window regulator switch in front passenger door E107 . . . . . . . . 248
3.2 Removing and installing switch module for driver side mirror adjustment . . . . . . . . . . . . . . 248
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3.3 Removing and installing driver side interior locking button for central locking system E308
........................................................................ 249
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Components - front door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
3.5 Removing and installing switch module for driver side window lift . . . . . . . . . . . . . . . . . . . . 250
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3.6 Removing and installing remote release button for fuel filler flap and rear lid E463 and key
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operated switch to block release of rear lid remote E232 . . . . . . . . . . . . . . . . . . . . . . . . . . 252

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4 Lights and switches in rear doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
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4.1 Components - front door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
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regulator switch, in door E54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
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5 Lights and switches in luggage compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
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5.1 Removing and installing luggage compartment light W3 . . . . . . . . . . . . . . . . . . . . . . . . . . Prote AG.
256
5.2 Removing and installing rear lid lock unit F256 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
6 Lights and switches in roof trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
6.1 Removing and installing front interior light and reading light (vehicles with no sliding
sunroof) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
6.2 Removing and installing front interior light and reading light (vehicles with sliding sunroof)
........................................................................ 261
6.3 Rear interior and reading light (vehicles without ATAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
6.4 Rear interior and reading light (vehicles with ATAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
6.5 Removing and installing front passenger side illuminated vanity mirror W14 and driver side
illuminated vanity mirror W20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
6.6 Removing and installing garage door operating unit E284 . . . . . . . . . . . . . . . . . . . . . . . . 271
7 Lights and switches in centre console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
7.1 Removing and installing TCS and ESP button E256 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
8 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
8.1 Removing and installing treble tone horn H2 and bass tone horn H7 . . . . . . . . . . . . . . . . 274
8.2 Checking treble tone horn H2 and bass tone horn H7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
9 Immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
9.1 Immobilizer control unit J362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
9.2 Immobilizer reader coil D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
9.3 Ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
10 Anti-theft alarm system (ATAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
10.1 Activating and deactivating anti-theft alarm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
10.2 Removing and installing anti-theft alarm ultrasonic sensor G209 . . . . . . . . . . . . . . . . . . . . 278
10.3 Removing and installing vehicle inclination sender G384 . . . . . . . . . . . . . . . . . . . . . . . . . . 278
10.4 Central locking and anti-theft alarm system aerial R47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
10.5 Alarm horn H12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
1 Vehicle Diagnosis, Testing and Information Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
1.1 Connecting vehicle Diagnosis, Testing and Information System VAS 5051A . . . . . . . . . . 281
2 Removing and installing fuse holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
2.1 Removing and installing fuse holder on left of dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . 283
3 Removing and installing relay carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
iv Contents
3.1 Removing and installing relay carrier with safety cut-out on left of dash panel . . . . . . . . . . 285
3.2 Removing and installing relay carrier on onboard supply control unit, on left of dash panel
........................................................................ 286
4 Electronics boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
4.1 Removing and installing electronics box on left in engine compartment . . . . . . . . . . . . . . 288
5 Control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
5.1 Onboard supply control unit J519 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
5.2 Data bus diagnostic interface J533 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
5.3 Central control unit for convenience system J393 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
5.4 Trailer detector control unit J345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
6 Wiring harness and connector repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
6.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
6.2 General notes concerning repairs to vehicle electrical system . . . . . . . . . . . . . . . . . . . . . . 302
6.3 Notes on repairs to wiring harness and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
6.4 Supplementary notes on repair of CAN bus wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
6.5 Wiring harness repair set V.A.G 1978 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
7 Renewal of aerial wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
7.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
7.2 Assembly overview - an aerial wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
7.3 Installing a new aerial wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
8 Torque settings: Cables . . . . . . . . . . . . . . . A.G. ..V.ol.ks. w. a.g.en. A. . . . . . . . . . . . . . . . . . . . . . . . . . . 307
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8.1 Torque settings: Electronics box in Vleft wage
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8.2 Torque settings trailer detectorisecontrol
d b unit J345 . . . . . . . . . . . . . .ua. r.an. . . . . . . . . . . . . . . . 307
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Contents v
AG. Volkswagen AG d
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vi Contents
27 Starter, current supply, CC

1 Battery
WARNING
Danger of injury! Observe warning notices and safety regula

tions page 2 !
Caution
To prevent damage to the battery and vehicle, the following

should be observed concerning types of battery page 1 .
1.1 Fundamentals for batteries

To ensure long use of the battery, the battery must be checked,
serviced and maintained as per instructions in this Manual.
Apart from supplying energy for starting the engine, the battery
has other tasks: it acts as a buffer and supplies electrical energy
to the complete vehicle electrical system.
Note
Observe Self-study programme No. 234 ; vehicle batteries .
1.2 Types of battery AG. Volkswagen AG d

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Low maintenance battery with liquid electrolyte (wet battery). s ce
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These batteries are recognised by the removable cell plugs.

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Lead-acid battery, electrolyte level must be checked regularly and
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These batteries are often equipped with a magic eye. The magic
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1.2.2 Maintenance-free battery

Maintenance-free battery with liquid electrolyte (wet battery).
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These batteries have a cover over the cells instead of cell plugs.
The cover seals the battery after initial filling during production.
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Lead-acid battery, where electrolyte need not be topped-up with

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1. Battery 1
These batteries are often equipped with a magic eye. The magic
eye provides information concerning the level of the electrolyte
and the charge state of the battery.
1.2.3 Absorbent glass mat (AGM) battery

Maintenance-free battery with a contained electrolyte.
Lead-acid battery where the electrolyte is contained within a mi
croscopic glass mat (AGM). The battery is sealed and fitted with
valves.
AGM is the abbreviation for Absorbent Glass Mat.
Note
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The procedure for checking and testing
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The procedure for checking and testing gel and absorbent
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1.3 Warning notices and safety regulations

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1.3.1 Dangers when handling vehicle batter

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Recognition and avoidance of dangers
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Batteries can be dangerous. These dangers can be avoided when
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the warnings on the battery and in the owners/instruction manual
and in ELSA are observed.
2 Rep. Gr.27 - Starter, current supply, CC

WARNING
Untrained personal e.g. apprentices, trainees etc. may

only work on batteries when supervised by a vehicle me
chanic/foreman or vehicle electrician/foreman.
Acid is highly corrosive. There is a considerable danger of
acid burns if personal do not handle batteries correctly.
Therefore suitable measures must be taken to ensure that
equipment/solutions etc. are available to neutralize acid
burns. A suitable solution is: e.g. a soap solution.
If electrolyte leaks from a battery it may cause skin burns
and acid corrosion, rusting on the vehicle. This may dam
age safety relevant components on the vehicle.
The gas which forms when charging and the gas which
may escape through vent valves is explosive. In extreme
cases a battery may explode if the battery is not handled
correctly.
It is prohibited to cause sparks through grinding, welding,
cutting operations and use naked lights in the vicinity of
batteries. Smoking is also prohibited. Sparks must also
prevented through electrostatic discharge, therefore al
ways earth through vehicle body etc. before touching
battery.
Only work on batteries in well ventilated and suitable
rooms.
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1. - Fires, ssparks,
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2. - Wear eye protection before commencing work on battery.

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3. - Keep children away from acid and batteries.

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4. - Disposal: old batteries are classed as hazardous waste. They

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may only be disposed of through a suitable collection centre and

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only in accordance with respective legislation.

5. - Never dispose of old batteries in household waste system!
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6. - There is a danger of an explosion when working with batteries.

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A highly explosive gas is produced when batteries are charged.

7. - Follow instructions concerning batteries, in ELSA "electrical
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8. - Battery acid is very caustic, therefore wear eye protection and

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gloves when working with batteries. Do not tilt battery. Acid can
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1. Battery 3
1.4 Battery terminal connection
Caution
To prevent damage to the battery terminal clamps and battery

terminals, the following should be observed:
The battery terminal clamps should only be fitted by hand
and without using force.
Battery terminals should not be coated with grease.
The battery terminal clamps should be fitted so that the
battery terminal is either flush with the clamp or protruding
from it.
Once the battery terminal clamps have been tightened to
the specified torque, the threaded connections should not
be tightened any further.
The tightening torque for the battery terminal clamps -1- and the
additional clamps-2- can be found in this table Tightening tor
ques: Battery page 36 .
AG. Volkswagen AG d
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2 Checking battery
WARNING

tions page 2 !
Caution

2.1 Procedure when checking the battery

Carry out procedure in sequence as follows:
AG. Volkswagen AG d
1. Visual check page 5 . lksw
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2. Checking battery with a magicised eye page 6 or checking
b ara
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a low maintenance battery
ut
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3. Check no load voltage
s of battery page 10 .
ce
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4. Perform a battery load test using battery tester with printer
an
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-VAS 5097 A- page 12 .
rm
ab
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2.2 Visual check
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WARNING
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tions page 2 ! rrectness of i
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It is essential first to check the external condition, the terminals of

the battery and that the battery is seated securely visually before
performing more extensive tests.
nform
mercia
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Caution
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The battery will be damaged if the battery is not secured

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Vibrations shorten the life of the battery, there is a danger

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securing plate may damage the battery housing. rig ht
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Check battery is securely seated, if necessary tighten se cted agen
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curing bolt to specified torque setting. page 36
Whether the battery housing is damaged: Check whether the

battery housing is damaged. Electrolyte can leak out if the
housing is damaged. If battery acid leaks out, serious damage
to the vehicle could be caused. Treat areas of the vehicle af
fected by leaked battery acid immediately with acid neutraliser
or a soap solution.
Whether the battery terminals (battery wiring/cable connec
tions) are damaged. Check whether the battery terminals (bat
tery wire connections) are damaged. The necessary contact
at the terminal clamps cannot be guaranteed if the terminals
are damaged. When connecting clamps to the terminals, tight
2. Checking battery 5
en the clamps to the torque specified in this workshop manual.

If the clamps are not correctly seated and tightened, the wiring
could burn, which could result in electrical system malfunc
tions. Which will cause malfunctions in the electricalAG. Volsystem.
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Therefore it can no longer be guaranteed Volkswthat the vehicle will oes not g
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2.3 Checking battery with magic eye ss
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WARNING
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tions page 2 !
, is n
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spec
es, in part or in w
The magic eye (condition indicator) provides information on the
t to the co
electrolyte level and condition (charge state) of the battery.
Batteries with a magic eye are produced in two versions:
rrectness of i
Low maintenance page 1
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Maintenance-free page 1
nform
ercia
Note
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tion in
Because the magic eye is located in only one cell, the display
r
te o
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applies only to this cell. An exact determination of battery's con
s
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dition is only possible through a load test page 12 .
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Before performing a visual check, tap the magic eye lightly and Cop py
carefully with the handle of a screwdriver.
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The air bubbles, which can influence the display, will dissipate
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when doing this. The colour display of the magic eye will therefore
Prote AG.
be more accurate.
Note
Air bubbles can form below the magic eye particularly when
the battery is being charged, including during normal vehicle
operation. These falsify the colour display of the magic eye.
The magic eye can be located at various positions on the bat
tery.
Three different colour displays are possible:

Green, battery is charged sufficiently.
Black, Battery partly discharged, charge state < 65 % or
completely discharged.
Colourless or yellow, battery must be renewed.
Note
Charging battery with battery charger -VAS 5095 A-

page 15 .
Charging battery with battery charger -VAS 5900-
page 19 .

2.4 Checking low maintenance battery
WARNING AG. Volkswagen AG d

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Danger of injury! Observe warning noticesiseand
d b safety regula ara
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tions page 2 ! hor eo
aut ra
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un
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This battery is low maintenance this means the electrolyte level
an
d
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must be checked and occasionally topped-up with distilled water
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2.4.1 Checking electrolyte level of battery
, is n
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Check electrolyte level on housing:
es, in part or in w
t to the co
Check electrolyte level via -min./ max.- marking on the battery
housing.
The electrolyte level is OK when the fluid level is at the max.
rrectness of i
marking.
l purpos
If the electrolyte level is below the -max.- marking:

Replenished with distilled water page 7 .
nform
ercia
Check electrolyte level in the cells:

m
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Switch off the ignition and all electrical consumers.
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If fitted, remove the protective foil on the cell sealing plug.
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The foil with the warning notices must remain on the battery. co Vo
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Remove cell sealing plugs.

Check the electrolyte level of the battery cells.
The electrolyte level is OK when the fluid level -1- is the same
height as the plastic peg.
Note
The plastic peg corresponds to the max. marking.
If electrolyte level is OK:

Check the cell sealing plugs and the O-ring seals for damage.
Damaged parts must be replaced.
Seal the cells with the cell sealing plugs.
If the electrolyte level is under the plastic peg:
Replenished with distilled water page 7 .
2.4.2 Topping up with distilled water

Special tools and workshop equipment required
Battery filler bottle -VAS 5045/-
n AG. Volkswagen AG do
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Caution
es, in part or in w
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When filling up with undistilled water or electrolyte the bat
tery will be damaged. Top up with distilled water only.
rrectness of i
The battery may be damaged when the cells are overfilled.
l purpos
When topping up use only the battery filling bottle -VAS

5045/- . The construction of the filler neck prevents an
overfilling of the battery cells.
nf
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orm
m
atio
om
Check the electrolyte level of the battery page 7 .
n in
or c
thi
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Note
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The foil with the warning notices must remain on the battery.
Prote AG.
Remove cell sealing plugs.

Replenish with distilled water using battery filling bottle -VAS
5045/- . When the max. level is reached the flow is interrupted
automatically.
Check the cell sealing plugs and the O-ring seals for damage.
Seal the cells with the cell sealing plugs.
Check no load voltage of battery page 10 .
Perform battery load/discharge test page 12 .
2.4.3 Check electrolyte density


Commercially available hydrometer
Check the electrolyte level of the battery page 7 .

Note
wage es n
The foil with the warning notices must remain on the battery.
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oris tee
Remove cell sealing plugs. au
th or
ac
ss
Draw electrolyte off a cell using a hydrometer until the float
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swims unhindered.
du
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itte
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erm
The electrolyte density is determined by the float position in the
ab
ility
battery electrolyte. The value can be read from the float scale.
ot p
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Electrolyte density Charge Voltage
hole
spec
1.28 g/cm3 100 % 12,7 V
es, in part or in w
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1,21 g/cm3 60 % 12,3 V
1,18 g/cm3 40 % 12,1 V rrectness of i
1,10 g/cm3 0% 11,7 V

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Note
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Checking electrolyte density directly after topping up with distilled

thi
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water will lead to erroneous results. Check electrolyte density only

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after charging the battery.

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Check the cell sealing plugs and the O-ring seals for damage. C py
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Seal the cells with the cell sealing plugs. cted agen
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2.5 Check no load voltage of battery
WARNING
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Danger of injury! Observe warning notices
olks and safety regula
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tions page 2 ! byV gu
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The no load voltage test is used to determine the capacity of the
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battery.
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Note
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The battery must not be charged or discharged for at least 2 hours
hole
spec
before making the measurements. Charging or discharging dur
es, in part or in w
ing this period falsify the test result.
t to the co
No load voltage Charge Condition of battery
rrectness of i
11,70 V 0% Discharged, no capacity. Heavily discharged.
l purpos
page 27 .
12,20 V 50 % Over a period of time sulphate crystals build-up which can
nf
ercia
only be reversed using a considerable amount of energy.
or
At the same time the active mass expands greatly, which
m
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can cause cracks, which leads to heavy corrosion at the
om
n in
positive plate.
or c
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12,35 V 65 % On batteries with a magic eye, the display will change

t
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from green to black.

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The battery should be recharged on new/vehicles which

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have been stored.
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12.70 V 100 % Full capacity.
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Hand multimeter -V.A.G 1526 B-
Switch off ignition and all electrical consumers and pull out
ignition key.
Disconnect negative terminal on battery page 29 .
Wait at least 2 hours. The battery must not be charged or dis
charged within this period.
Check battery no load voltage with hand multimeter -V.A.G
1526 B- .

Measured value Measure to be performed

No load voltage 12.5 V No load voltage is OK, perform
a battery load test page 10 .
No load voltage < 12.5 V Charge battery page 15 .
If the battery has been recharged as a result of the no load test,
proceed as follows:
Wait at least 2 hours. The battery must not be charged or dis
charged within this period.
Check battery no load voltage again with hand multimeter -
V.A.G 1526 B- .
If after the loading process the battery no load voltage is < 12.5 V,
renew battery page 31 .
2.6 Battery tester with printer -VAS 5097 A-
WARNING

tions page 2 !
It is not necessary to remove or disconnect battery when using

battery tester with printer -VAS 5097 A- .
Battery tester with battery tester with printer -VAS 5097 A- can be
used to test 12 V starter batteries according to
80 - 499 A A low-temperature test current according to DIN
(Deutsche Industrie Norm (German Industrial Standard))1)
95 - 574 A A low-temperature test current according to IEC
(International Engineering Consortium)
ks AG. Vol wagen AG d
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136 - 855 A VAollow-temperature
ksw test current
es n
otaccording
gu
to EN/
SAE (European
sed by
Norm/Standard of Automotive arEngineers)
an
ri tee
1) Batteriesho
aut with a low-temperature test current of 520 A according toorDIN
ac can be
testedsusing
s setting for 499A according to DIN.
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pt
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For test purposes the battery is loaded with a current which is

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similar to the starting current required to start the vehicle. The

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battery is assessed on this loading and the result is printed out.

ility
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Note
spec
es, in part or in w
t to the co
Observe the Instruction Manual for battery tester with printer

-VAS 5097 A- or sticker Brief instructions for battery tester
with printer -VAS 5097 A- stuck on the unit or table Low-tem
rrectness of i
perature current. page 13

l purpos
Observe battery manufacture's handling instructions!

nform
mercia
at
om
ion
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or
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2.6.1 Description of battery tester with printer

-VAS 5097 A-
Battery tester with printer -VAS 5097 A-
1 - Green LED, unit operating
2 - Red LED, unit reverse-polarity connected
3 - Red LED, battery cannot be tested, recharge battery.
4 - Start tester
5 - Low-temperature current selection switch
6 - ON/OFF and functions switch
7 - Selection switch (battery tester to pick-off point on battery/
external test point in engine compartment) AG. Volkswagen
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8 - Button to advance paper Volks ot g
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9 - Printer thoris tee
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2.6.2 Battery load test using battery tester
ce
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pt
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with printer -VAS 5097 A-
itte
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WARNING
, is n
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hole
spec
es, in part or in w
tions page 2 !
t to the co
rrectness of i
Battery tester with printer -VAS 5097 A-

l purpos
nf
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orm
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atio
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Perform battery load test:
Set low-temperature test current for battery in Ampere (A) ac
cording to DIN standard.
If the battery values are shown in IEC or EN/ SAE instead of DIN
then convert figures using table
2.6.3 Table: low-temperature test current, page 13 or using
table on unit.
Select low-temperature test current via low-temperature test
current selection switch page 12 .
Select measuring range 80 - 379 A or 380 - 499 A with ON/
OFF and functions switch page 12 .
Connect red terminal + of unit to positive terminal.

Connect black terminal - of unit to negative terminal.
Note
Ensure test clamps have a good contact!
Select point of connection of test terminals with selection

switch page 12 .
1- Connected directly to battery.
2- Connected to external test points in engine compartment.
Check that the figures given on the battery are correct for the
settings on the battery tester.
Press start test button page 12 .
The green LED lights up page 12 . The test program runs
through automatically. The test result is printed out by the printer
page 14 .
Switch off unit page 12 .
Remove test terminals.
Note
The test is completed after about 20 seconds.

The result of the test is printed out by the printer.
Perform test once only. Repeating the test falsifies the results.
2.6.3 Table: low-temperature test current

. Volkswag
Low-temperature
ksw
agen
AG testecurrent
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oesin A
ol not
V
EN/ SAE ed IEC
by guara DIN
ris nte
136 - 17 tho 95 - 124 eo
80 - 104
au ra
c
178 - 219 ss 125 - 154 105 - 129
ce
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nl
pt
220 - 261 155 - 184 130 - 154

du
an
itte
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262 - 303 185 - 214 155 - 179

erm
ab
ility
304 - 345 215 - 244 180 - 204

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346 - 387 245 - 274 204 - 229

h re
hole
388 - 429 275 - 304 230 - 254

spec
es, in part or in w
430 - 471 305 - 334 255 - 279

t to the co
472 - 513 335 - 364 280 - 304

514 - 555 365 - 394 305 -329
rrectness of i
556 - 597 395 - 424 330 - 354

l purpos
598 - 639 425 - 454 355 - 379

640 - 657 455 - 464 380 - 389
nform
ercia
658 - 675 465 - 474 390 - 399

m
at
676 - 693 475 - 484 400 - 409

om
ion
c
694 - 711 485 - 494 410 - 419

in t
or
his
te
712 - 729 495 - 504 420 - 429

a
do
priv
730 - 747 505 - 514 430 - 439

um
for
en
ng
748 - 765 515 - 524 440 - 449

t.
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766 - 783 525 - 534 450 - 459
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784 - 801 535 - 544 460 - 469
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Low-temperature test current in A

EN/ SAE IEC DIN
802 - 819 545 - 554 470 - 479
820 - 837 555 - 564 480 - 489
838 - 855 565 - 574 490 - 4992)
2) Batteries with a low-temperature test current of 520 A according to DIN can be tested using setting for 499A according to DIN.
2.7 Evaluating test result

Because of the high load on the battery during this test (a high
current flows) the battery voltage drops.
If the battery is OK the voltage value only lowers to the mini
mum voltage.
If the battery is defective or has a low charge the battery volt
age quickly drops below the minimum voltage.
This low voltage value remains over a long period and the
voltage only increases again slowly after the test has been
completed.
2.7.1 Comments concerning test print out

1- Measuring range set on tester.
2- Diagram -arrow- indicates battery condition.
3- Test result.
4- Battery voltage during load test.
AG. Volkswagen AG d
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5- Vehicle data and date. VoMust
lksw be completed by test person
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nel. sed by ua
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Note
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The print out is required for warranty purposes.

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2.7.2 Assessing test results

rrectness of i
Battery tester print out Measure to be performed

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Starting power very good Battery OK

Start output good Battery OK
nf
ercia
Starting power sufficient Charge battery page 15

orm
and repeat battery load test 3)

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atio
Starting power poor

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Starting power very poor

or
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Not capable of being tested

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3) If after battery has been recharged Starting output sufficient, Starting output
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poor, Starting output very poor or Cannot be tested is shown, the battery op
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AG. Volkswagen AG d Jetta 2005 , Bora 2006
agen
olksw Electrical
oes
not System - Edition 05.2005
yV gu
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WARNING
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tions page 2 !
h re
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Caution
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ercia
3.1 Battery charger -VAS 5095 A-

m
at
This chapter describes the basic functions of the battery charger
om
ion
-VAS 5095 A- . For additional information refer to Operating
c
in t
or
instructions for battery charger -VAS 5095 A- .
his
ate
do
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Note
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Observe Operating instructions for battery charger -VAS
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5095 A- .
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Observe battery manufacture's handling instructions!
3.1.1 Description of battery charger -VAS

5095 A-
Battery charger -VAS 5095- is suitable for charging
Wet batteries (genuine VW batteries from 2004 with transpar
ent battery housing and black cover).
Absorbent glass mat batteries (genuine VW batteries from
2004 with black housing).
The battery charger charges without peaks in amperage or volt
age. This will not adversely effect the onboard electronics. The
battery can remain in the vehicle while it is being charged and
need not be disconnected.
Battery charger -VAS 5095 A-
1 - ON / OFF switch (0 = charger OFF)
2 - Charging current indicator (I > 12 A)
3 - Charging current indicator, battery partially charged > 90 %
4 - Maintaining charge, lights up green when battery is fully charg
ed
5 - Malfunction indicator
6 - Support mode indicator
7 - Support mode/normal mode changer-over switch
8 - Charger cable posts, red terminal +, black terminal -
9 - Battery type change-over switch (on base of charger unit)
3. Charging battery 15
3.1.2 Charging battery with battery charger -

VAS 5095 A-
WARNING

tions page 2 !

Caution AG. Volkswagen AG d

agen oes
olksw not
Always set battery type 2.4 V/C (Volt/Cells) when ycharging!
V gu
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This applies for all batteries. horis nte
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Note
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ility
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The battery must have a temperature of at least 10 C.

wit
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If the battery has cell sealing plugs, do not open them while h re
hole
spec
the battery is being charged.
es, in part or in w
t to the co

Check setting for battery type on type of battery switch
rrectness of i
page 15 . Must be set to 2.4 V/C (Volt/Cells).

l purpos
Connect red terminal clamp + of charger unit to positive ter

minal on battery.
nform
ercia
Connect black terminal clamp - of charger unit to negative

m
at
terminal on battery.
om
ion
c
in t
Switch on battery charger page 15 .

or
his
ate
The charging current indicators page 15 -2- and -3- light up

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priv
yellow. When only the light emitting diode (LED) -3- lights up yel
um
for
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low, battery is partially discharged (approx. 90 %).

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If the LED lights up green page 15 -4- the charger has switched
. C rig
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to "maintaining charge". The battery is fully charged. py by
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Switch off charging unit page 15 . Prote AG.
Remove charger unit terminals from battery terminals.

3.1.3 Charging totally discharged battery with

battery charger -VAS 5095 A-
WARNING

tions page 2 ! en AG. V
olkswagen AG
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olks not
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The charger unit automatically recognises totally tho discharged bat
ris nte
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teries and initiates a gentle charging procedureau with a low charg ra
c
ss
ing current. The charging current is automatically adapted to suit
ce
le
the charge condition of the battery.
un
pt
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Note
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Observe notes in chapter page 27 .
ole,
spec
urposes, in part or in wh
The battery voltage must be at least 0.6 V.
t to the co
Charge battery page 16 .
rrectne
3.1.4 Charging battery in support mode with
battery charger -VAS 5095 A-
ss o
cial p
f inform
WARNING
mer
atio
om
n
c
i
or
n
tions page 2 !
thi
te
sd
iva
o
pr
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fo
en
When in support mode the battery charger -VAS 5095 A- replaces
ng
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a defective vehicle battery whilst it is being exchanged. The on Cop py
board supply remains intact. The vehicles electrical equipment
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(e.g. electric windows) can be used. cop Vo
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AG.
Caution
Always set battery type 2.4 V/C (Volt/Cells) when in sup

port mode! This applies for all batteries.
The battery charger -VAS 5095 A- terminal clamps must
remain in contact with the battery terminal clamps whilst
the battery is being exchanged.

Set support mode/normal mode change-over switch to
page 15 support mode.
minal of vehicle.
terminal of vehicle.
Check setting for battery type on type of battery switch
page 15 . Must be set to 2.4 V/C (Volt/Cells).
Switch on battery charger page 15 .
The yellow LEDs page 15 -6- and -3- light up.
AG. Volkswagen AG d
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Note by Vol not
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A minimum load of 0.6 A (e.g. parking light) must be switched
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on, otherwise support mode is not possible. ss c
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During the support mode the current draw is limited to 5 A.
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Switch on vehicle parking light.
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Exchange battery page 31 .
h re
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spec
Switch off charging unit page 15 .
t to the co
Remove charger unit terminals from battery terminals.
Set support mode/normal mode change-over switch to
page 15 normal mode again.
rrectne
3.1.5 Charging battery in buffer/ maintenance
ss
mode with battery charger -VAS 5095 A-
o
cial p
f inform
mer
WARNING
atio
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thi
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tions page 2 !
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In the buffer mode the battery charger -VAS 5095 A- is charged Cop py
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correctly and is maintained in a fully charged condition. opyri
gh by
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Proceed as for charging battery page 16 .
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cted agen
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Note
When a battery is being charged in the buffer mode and a

consumer draws current from the battery, the battery charger
-VAS 5095 A- automatically compensates the charge.
The buffer mode can be continued for an unlimited period.
The battery is always ready for use.
Observe battery manufacture's maintenance instructions!

3.2 Battery charger -VAS 5900-
WARNING

tions page 2 !
This chapter describes the basic functions of the battery charger

-VAS 5900- . For additional information refer to Operating in
structions for battery charger -VAS 5900- .
Note
AG. Volkswagen AG d
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Observe Operating instructions for battery chargerby Vo
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Observe battery manufacture's handlingssinstructions!
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3.2.1 Description of battery charger -VAS
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Battery charger -VAS 5900- is suitable for charging
h re
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spec
Wet batteries (genuine VW batteries from 2004 with transpar
es, in part or in w
ent battery housing and black cover).
t to the co
Absorbent glass mat batteries (genuine VW batteries from
2004 with black housing).
rrectness of i
Battery charger -VAS 5900-
l purpos
1 - Display
2 - Adjustment button Up
nform
ercia
3 - Adjustment button Down

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tion in
4 - START / STOP
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5 - INFO do
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3.2.2 Charging battery with battery charger -
yi Co
Cop py
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WARNING

tions page 2 !
AG. Volkswagen AG d
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Jetta 2005 , Bora oris 2006 nte
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Electrical System
s au - Edition 05.2005 ra
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es, in part or in w
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Note
com
tion in
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If the battery has cell sealing plugs, do not open them while
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Cop py
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Switch off the ignition and all electrical consumers. rig ht
py by
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Connect charger unit plug to power supply. The last selected Prote
cted AG.
agen
operating mode will appear on display page 19 .
Set battery to respective operating mode with INFO .
In the display the symbol -1- for standard charge for wet batter
ies or the symbol -2- for standard charge for gel/absorbent glass
mat batteries will appear.
Set battery capacity (Ah) of battery for charging using respec
tive button Up or Down .
Connect red terminal clamp + to positive terminal on battery.
Connect black terminal clamp - to negative terminal on bat
tery.
The charger unit recognises the voltage required for the connec
ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.
At a charge condition of approx. 80 - 85 % the charger unit

switches to the final charge mode. The fourth bar appears in
display -1-. The battery is ready for use.

At a charge condition of 100 % all bars appear in display.
Note
In the battery type standard charge the parallel use of con

sumers while charging is possible. The charging period will be
longer.
The battery charger will switch to maintenance mode after
about 1-7 hours, depending on type of battery. To achieve a
100 % charge the battery should remain connected for this
period.
Possible faults and fault rectification:

1- Displayed battery voltage is not as per nominal voltage:
Press respective button Up or Down until charging
sequence starts.
2- Displayed battery voltage is not as per nominal voltage
charging sequence already started: en AG. V
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Press respective button Up or or
Down uthuntil charging eo
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sequence starts again. ss a c
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3- Battery charger does not detect a battery, when battery volt
pt
an
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age is less than 2 V:

itte
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Display remains unchanged.
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The battery type and ampere hours (Ah) as set is displayed.
h re
hole
spec
Ending battery charging sequence:
es, in part or in w
t to the co
Press START / STOP .
Disconnect black terminal clamp - of charger unit from neg
rrectness of i
ative terminal on battery.
Disconnect red terminal clamp + of charger unit from nega
l purpos
tive terminal on battery.
nform
Pull charger unit plug out power supply socket.
mercia
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3.2.3 Charging battery in service mode with
ion in
r
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battery charger -VAS 5900-

thi
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WARNING
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Danger of injury! Observe warning notices and safety regula yri
gh by
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tions page 2 ! cop Vo
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Prote AG.
Caution
The operating mode service charge is not permitted on VW

vehicles as the voltage peaks will damage the onboard elec
tronics.
If there is a requirement to use service charge the battery
must be disconnected from the onboard supply.
Caution
When charging always set the battery charger to the correct

type of battery Operating instructions for battery charger -
VAS 5900- !
Service charge must only be used for:
Wet batteries, where distilled water can be replenished.
Gel/absorbent glass mat batteries.
Do not use operating mode service charge with maintenance-
free wet batteries page 1 .
The operating mode service charge (SERV) is only used on

suspect defective batteries (e.g. sulphation). The battery will be
charged to maximum specific gravity and the plates will be reac
tivated (dissipation of sulphur layer).
AG. Volkswagen AG d
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Note
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
Connect charger unit plug to power supply. The last selected

nform
ercia

m
at
om
ion
In the display the symbol -1- for service charge for wet batteries
c
in t
or
or the symbol -2- for service charge for gel/absorbent glass mat
his
ate
batteries will appear.

do
priv
cum
or

f
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t.
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Cop py
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Connect red terminal clamp + to positive terminal on battery. rig ht
py by
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Connect black terminal clamp - to negative terminal on bat cted agen
Prote AG.
tery.
The charger unit recognises the voltage required for the connec
ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.

AG. Volkswagen AG d
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olksw not
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d by gu
ara Electrical System - Edition 05.2005
rise nte
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At a charge
ss au
condition of approx. 80 - 85 % the charger unit
ra
c
switches to the final charge mode. The fourth bar appears in
ce
e
nl
display -1-. The battery is ready for use.
pt
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Note
wit
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h re
The success of the service charge depends on the severity of
hole
spec
the sulphation of the battery.
es, in part or in w
t to the co
Possible faults and fault rectification:
1- Displayed battery voltage is not as per nominal voltage:
rrectness of i
l purpos
sequence starts.
nf
2- Displayed battery voltage is not as per nominal voltage
ercia
o
charging sequence already started:
rm
m
atio
m
Press START / STOP twice.

o
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or c
thi
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t
sd
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sequence starts.
o
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m
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3- Battery charger does not detect a battery, when battery volt

t.
yi Co
age is less than 2 V:
Cop py
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yri
Display remains unchanged. p by
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The operating mode and ampere hours (Ah) as set is displayed.
Prote AG.

Press START / STOP .
ative terminal on battery.
3.2.4 Charging totally discharged battery with

WARNING

tions page 2 !
AG. Volkswagen AG d
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Jetta 2005 , Bora 2006 horis nte
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Electrical System - Edition 05.2005 aut ra
ss c
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pt
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Caution
y li
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ab
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The terminal polarity protection in operating mode charg
wit
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ing totally discharged batteries/support mode is not ac
h re
tive. Connect battery charger terminal clamps correctly to
hole
spec
battery terminals.
es, in part or in w
t to the co
When charging always set the battery charger to the cor
rect type of battery Operating instructions for battery
charger -VAS 5900- !
rrectness of i
Totally discharged battery is not recognised by battery
l purpos
charger page 27 .
Do not press START / STOP button when charger unit
nform
ercia
cables are connected incorrectly. The charger unit may be
damaged. m
at
om
ion
c
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or
his
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Batteries with a voltage of less than 2 Volt will not be recognised

a
do
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automatically by battery charger -VAS 5900- .

p
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for
en
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n
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Cop py
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rig ht
py by
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Prote AG.
Note




In the display the symbol -1- for service charge for wet batteries
or the symbol -2- for service charge for gel/absorbent glass mat
batteries will appear.
Connect red terminal clamp + to positive terminal on battery.
Connect black terminal clamp - to negative terminal on bat
tery.
Press START / STOP for approx. 5 seconds. The menu
charging totally discharged batteries/support mode will be
activated.
Press respective button Up or Down to set the respec
tive battery voltage (6 V, 12 V or 24 V).
Note
If a button is not pressed within 5 seconds the charger will return

to the main menu (select operating mode).
Confirm the selected battery voltage with START / STOP .

Then follows the enquiry for "is charger cable terminal polarity
correct".
Check polarity of charger unit cables.
Confirm polarity of charger unit cables with START / STOP .
Charger will start charging sequence for totally discharged bat
tery.
gen AG
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Press START /d bSTOP
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Disconnect au
thoblack terminal clamp - of charger unit from eneg
or
ac
ative terminal
ss on battery.
ce
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nl

pt
du
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itte

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ab

ility
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wit
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3.2.5 Charging battery in support mode with

hole
spec

es, in part or in w
t to the co
WARNING
rrectness of i

l purpos
tions page 2 !
nf
ercia
orm
m
atio
om
n in
or c
thi
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f
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t.
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Cop py
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gh ht
pyri by
Vo
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cted agen
Prote AG.
Caution
The terminal polarity protection in operating mode charg

ing totally discharged batteries/support mode is not ac
tive. Connect battery charger terminal clamps correctly to
battery terminals.
When charging in support mode always set the battery
charger to the correct type of battery Operating instruc
tions for battery charger -VAS 5900- !
Do not press START / STOP button when charger unit
cables are connected incorrectly. The charger unit may be
damaged.
When in support mode the battery charger -VAS 5900- replaces

a defective vehicle battery whilst it is being
wage
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Volkswagen AGThe on
does
board supply remains intact. The yV
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(e.g. electric windows) canisebe
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Special tools and workshop
sa
ut equipment required or
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ab
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nform
mer

atio
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o
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c
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Press START / STOP for approx. 5 seconds. The menu

te
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charging totally discharged batteries/support mode will be

i
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pr
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activated.
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t.
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Press respective button Up or Down to set the re . Cop py
spective onboard supply voltage (6 V, 12 V or 24 V).
t rig
gh ht
pyri by
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cted agen
Prote AG.
Note
If a button is not pressed within 5 seconds the charger will return

to the main menu (select operating mode).
Confirm the selected battery voltage with START / STOP .

minal of vehicle.
Then follows the enquiry for "is charger cable terminal polarity
correct".
Check polarity of charger unit cables.
Confirm polarity of charger unit cables with START / STOP .

The battery charger starts with support mode.

Exchange battery page 31 .
Press START / STOP . The support mode is terminated.
ative terminal of vehicle.
Disconnect red terminal clamp + of charger unit from positive
3.2.6 Charging battery in maintenance mode

with battery charger -VAS 5900-
WARNING

tions page 2 !
AG. Volkswagen AG d
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olksw not
yV gu
When the battery isisefully
d b charged the battery charger -VAS ar5900-
an
switches to maintenance
uthor
mode. tee
or
s a ac
Proceed as for charging battery page 19 .
s
ce
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nl
pt
du
At a charge condition of 100 % all bars appear in display. an

itte
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erm
ab
ility
ot p
Note
wit
, is n
h re
hole
When a battery is being charged in the buffer mode and a

spec
consumer draws current from the battery, the battery charger

es, in part or in w
t to the co
-VAS 5900- automatically compensates the charge.

The maintenance mode can be continued for an unlimited pe
riod.
rrectness of i
The battery is always ready for use.

l purpos
Observe battery manufacture's maintenance instructions!

nform
mercia
at
3.3 Totally discharged batteries

om
ion
c
in t
or
his
ate
WARNING
do
priv
cum
for
en
g

n
t.
yi Co
op
tions page 2 ! C py
ht. rig
rig ht
py by
co Vo
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A battery is designated totally discharged when the "no load" Prote AG.
voltage is less than 12.2 V.
Caution
Totally discharged batteries freeze prematurely.

Frozen batteries should no longer be used.
Note
Batteries that have not been used for a long time e.g. vehicles
that have been stored, will self-discharge.
In totally discharged batteries, the electrolyte is comprised al
most entirely of water because the acid content is so low.
Totally discharged batteries sulphate, that is, the entire plate
surfaces of the battery harden.
If a battery is recharged shortly after it has totally lost its AG. Volkswagen AG d
charge, the sulphation will dissipate. agen oes
olksw not
V gu
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If these batteries are not recharged the plates continue
rised
to nte
harden and the ability to recharge is reduced.autA reduction in
ho eo
ra
the battery output is the result. ss c
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un
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an
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itte
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Charge battery.
ility
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wit
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Charging battery with battery charger -VAS 5095 A- page 15 .
h re
ole,
Charging battery with battery charger -VAS 5900- page 19 .
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
n thi
te
sd
iva
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pr
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fo
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t.
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Cop py
t. rig
gh ht
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Vo
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by c lksw
cted agen
Prote AG.

4 Disconnecting and reconnecting bat

teries
WARNING

tions page 2 !
4.1 Disconnecting battery
Note
By disconnecting the battery earth wire (open circuit), safety

is ensured when carrying out work on the electrical system.
The battery positive wire need only be disconnected for re
moval of the battery.

Release catch -arrow- and take cover off battery box.
First unscrew battery earth clamp -1- from battery negative
terminal.
AG. Volkswagen AG d
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Then
ss unscrew battery positive clamp -2- from batteryc positive
terminal.
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
4.2 Connecting battery

nform
ercia
Caution
m
at
om
ion
c
in t
Observe instructions on connecting battery terminals

or
his
e
page 4 .
at
do
priv
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for
en
ng
t.
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Co
Cop py
t. rig
gh ht
pyri by
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Prote AG.
4. Disconnecting and reconnecting batteries 29

Torque wrench -V.A.G 1331-
Note
After connecting the battery and switching the ignition on the ESP
and TCS warning lamp -K155- lights up permanently. The warn
ing lamp goes out automatically if a distance of 15 to 20 km/h is
driven straight ahead. This activates the steering angle sender -
G85- again.
lkswage es n
o ot g
Caution d byV ua
ran
ir se tee
tho
or
Disconnecting and connecting the
ss
au
battery as described in the ac
Workshop Manual page 29 .
ce
e
nl
pt
du
an
itte
y li
erm
ab
Fit battery positive clamp -2- to positive terminal of battery and
ility
ot p
tighten securing bolt to specified torque setting page 36 .
wit
, is n
h re
Fit battery earth clamp -1- to negative terminal of battery and
hole
tighten securing bolt to specified torque setting page 36 . spec

es, in part or in w
t to the co
Carry out the procedures as detailed in the table.
Steps after connecting battery
rrectness of i
Procedures Performed
l purpos
Switch ignition on and off again

using ignition key
nf
ercia
Read fault memory: Guided

orm
fault finding using VAS 5051A .

m
atio
m
Clock: Check time on clock and

o
n in
or c
change as necessary.
thi
te
sd
a
Electric windows: Open all

iv
o
r
rp
cu
electric windows fully and close

o
m
f
en
ng
again.
t.
yi Co
op py
Functional check: of all electri t. C rig
gh ht
cal consumers. yri
p by
co Vo
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cted agen
If necessary, table can be printed out. Prote AG.

5 Removing and installing battery
WARNING

tions page 2 !
5.1 Models with a petrol engine

AG. Volkswagen AG d
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ot
wit
, is n
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es, in part or in w
Removing:
t to the co
Disconnect the battery page 29 .

rrectness of i
Pull panel of battery box out upwards in direction of arrow.

l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Unscrew securing bolt -1- and remove battery holder -2-.
co Vo
by lksw
cted agen
Prote AG.
5. Removing and installing battery 31

Fold handles -arrows- upwards and take battery out.

Installing:
Caution
A loosely fitted battery creates the following dangers:

Shortened service life due to damage from vibration (dan
ger of explosion).
The cells in the battery will be damaged if the battery is
not secured correctly.
Damage to battery housing by. Vclamping bracket (possi
olkswagen AG
bility of acid leaking,ktherefore
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does
n
costs).
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Poor crash safety
ise
db ua
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r tee
ho
aut or
ac
ss
Installation is performed in the reverse order of installation; when
ce
e
nl
pt
doing this, note the following:
du
an
itte
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erm
Tighten threaded connections to specified torque settings
ab
ility
page 36 .
ot p
wit
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After installing, check that battery is seated securely.
h re
hole
spec
Connect the battery page 29 .
es, in part or in w
t to the co
Caution
rrectness of i
Disconnecting and connecting the battery as described in the

l purpos
nf
ercia
or
5.2 Models with a diesel engine

m
m
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om
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c

or
thi
te
sd
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iv
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rp
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t.
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Cop py
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gh ht
pyri by
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by
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Prote AG.

AG. Volkswagen AG d Jetta 2005 , Bora 2006
agen oes Electrical System - Edition 05.2005
olksw not
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edb ara
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Spring-type clipthpliers
or -VAS 5024A- eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing:
l purpos
nf
ercia
o
For vehicles with a 1.9 l TDI engine:
rm
m
atio
m
Pull engine cover upwards -arrows A- and forwards

o
n in
c
-arrow B-.
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Disconnect connector -1- and loosen spring type clip -2- with
spring type clip pliers -VAS 5024A- .
Pull the vacuum hose -arrow- off air filter housing.

Unscrew air filter housing securing bolt -arrow-.
Unlock lugs -arrows- and take cover off.
lkswage es n
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byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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un
pt
an
d
Pull hose -arrow- off air filter housing and take hose out.
itte
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erm
ab
Pull air filter housing upwards out of brackets and remove.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
Pull panel of battery box out upwards in direction of arrow.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Unscrew securing bolt -1- and remove battery holder -2-.
AG. Volkswagen AG d
agen oes
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au ra
ss c
ce
e
nl
pt
du
an
itte
y li
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ab
Fold handles -arrows- upwards and take battery out.
ility
ot p
Installing:
wit
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hole
spec
Caution
es, in part or in w
t to the co
A loosely fitted battery creates the following dangers:
Shortened service life due to damage from vibration (dan
rrectness of i
ger of explosion).
l purpos
The cells in the battery will be damaged if the battery is

not secured correctly.
nf
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o
Damage to battery housing by clamping bracket (possi
rm
m
bility of acid leaking, therefore subsequent higher costs).
atio
om
n in
c
Poor crash safety

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Tighten threaded connections to specified torque settings gh ht
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page 36 . cop Vo
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After installing, check that battery is seated securely.
Caution


Jetta 2005 , Bora 2006 agen
AG. Volkswagen AG d
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6 Torque settings: battery
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Battery clamp to battery terminal M6 6 Nm
pe
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Additional clamp to battery terminal M6 6 Nm
wit
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clamp
hole
spec
Securing bolt of battery holder M8x35 20 Nm
es, in part or in w
t to the co
Air filter housing to body 10 Nm
rrectness of i
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mercia
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tion in
r
te o
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t.
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7 Starter
Caution

7.1 Checking starter -B-

Connect the vehicle diagnosis, testing and information system
-VAS 5051A- to page 281
Select guided fault finding in Vehicle Diagnosis, Testing and In
formation System -VAS 5051A- .
Using the Go to key, select Function/component selection
and the following menu items one after the other:
Body
Electrical System
AG. Volkswagen AG d
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27 - Starter, current supply Volksw
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es, in part or in w
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rrectness of i
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nform
mercia
at
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ion
c
in t
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ate
do
priv
cum
for
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t.
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7. Starter 37
7.2 Removing and installing starter, auto

matic gearbox
7.2.1 Vehicles with 1.6 l injection engine

equipment required
Torque wrench -V.A.G
1331-
1332-
Spring-type clip pliers -VAS
5024-
AG. Volkswagen AG d
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spec
Removing:
t to the co

Release spring-type clip -1- using spring type clip pliers -VAS
rrectne
5024- and remove securing bolt -2-.

Release hose -3- and pull it off the air filter housing.
ss o
cial p
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mer
atio
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n
c
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Rep. Gr.27 - Starter, current supply, CC
AG.
Pull air filter housing on right side upwards off rubber mounting
-arrow-.
Remove air filter housing from vehicle.
AG. Volkswagen AG d
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Push down protective cap orisin -direction of arrow- from solenoid
ed
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switch. aut
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un
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an
d
itte
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ab
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wit
is n
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spec
t to the co
rrectne
Unscrew positive wire -1- and disconnect connector from ter
minal 50 -2-.
ss o
Remove noise insulation General Body Repairs, Exterior;
cial p
f in
Rep. Gr. 50 ; Body front; Noise insulation .
form
mer
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n
c
i
or
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pr
cum
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fo
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t.
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Cop py
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Unscrew securing nut -1- from lower starter securing bolt.
cted agen
Prote AG.
Remove wiring retainer -2-.
7. Starter 39
AG. Volkswagen AG d
Electrical System - Edition 05.2005 lksw
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not
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Remove lower securing bolt of starter
horis -arrow-. nte
eo
aut ra
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ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
Unscrew securing nut -1- from upper starter securing bolt.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
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Remove upper securing bolt of starter -arrow-. Prote AG.
Unscrew earth wire securing nut -1- and place earth wire -2-
to one side.
Remove starter from vehicle upwards.
Installing:
Installation is carried out in the reverse order. When installing,
note the following:
page 97 .
7.2.2 Vehicles with 1.6 l FSI engine


AG. Volkswagen AG d
Torque wrench -V.A.G 1332- lksw
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not
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es, in part or in w
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Removing:
rrectness of i
l purpos
Push down protective cap in -direction of arrow- from solenoid

switch.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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Prote AG.

minal 50 -2-.
7. Starter 41

Remove lower securing bolt of starter -arrow-.
AG. Volkswagen AG d
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du
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nf
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Remove upper securing bolt of starter -arrow-.

rp
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t.
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Cop py
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gh ht
pyri by
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to one side.
Installing: AG. Volkswagen AG d
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Installation is carried out in the reverse order. Whenbyinstalling,
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note the following: rise
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Tighten threaded connections to specified ss a torque settings
u ra
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page 97 .
ce
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un
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7.2.3 Vehicles with 2,0 l FSI engine
h re
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spec
t to the co
equipment required
rrectne
1331-
ss o
1332-
cial p
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mer
5024-
atio
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Cop py
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Removing:
7. Starter 43
Disconnect connector -arrow-.
Unclip vacuum hose from its mounting -arrow-.
AG. Volkswagen AG d
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Loosen spring-type clip -arrow- from hose -1- using spring type
an
d
itte
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clip pliers -VAS 5024- .
erm
ab
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Pull hose -1- off air filter housing.
wit
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spec
t to the co
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Open retainer -arrow- on front side of air filter housing and take
form
mer
hose -1- off.

atio
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n
c
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-arrow-.
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Loosen spring-type clip -1- using spring typethoclip
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Pull hose -2- off pipe union.

un
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Carefully lift air filter housing upwards out of the vehicle taking
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into consideration the length of the hose.
pe
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Separate connector -arrow- on rear of air filter housing. rrectness of i
l purpos
nform
mercia
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tion in
r
te o
thi
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iva
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en
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t.
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Cop py
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7. Starter 45

switch.

minal 50 -2-. agen
AG. Volkswagen AG d
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Remove noise insulation General Body Repairs, Exterior; d by V gu
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Rep. Gr. 50 ; Body front; Noise insulation . rise nte
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un
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d
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ab
pe
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
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t.
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Co
Cop py
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gh ht
pyri by
Vo
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by
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Remove upper securing bolt of starter -arrow-. agen

AG. Volkswagen AG d
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nl
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du
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ab
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, is n
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spec
es, in part or in w
t to the co
to one side.
rrectness of i
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Installing:
nf
ercia
or
note the following:
m
m
atio
m

o
n in
or c
page 97 .
thi
te
sd
iva
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cu
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m
f
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
7. Starter 47
7.2.4 Vehicles with 2,5 l injection engine

equipment required
1331-
1332-
AG. Volkswagen AG d
agen
Spring-type clip pliers -VAS olksw
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not
5024- byV gu
ara
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nl
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du
an
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ab
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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atio
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n in
or c
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.
Removing:
Pull engine cover off upwards -arrows-.

Separate connector -1-, release spring-type clip -2- with spring

type clip pliers -VAS 5024- and pull off vacuum hose -3-.
Push down protective cap -direction of arrow- from solenoid

switch.
lkswage es n
o ot g
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a ac
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un
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d
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wit
is n
minal 50 -2-. h re
ole,
spec

t to the co
rrectness o
cial p
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mer
atio
om
Unscrew nut -1- from lower starter securing bolt.

c
i
or
n thi
te

sd
iva
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
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by
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Prote AG.
7. Starter 49
AG. Volkswagen AG d
agen oes
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ce
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nl
pt
du
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itte
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wit
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spec
Unscrew nut -1- from upper starter securing bolt.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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n in
or c
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Remove starter from vehicle downwards. t. Cop py
rig
gh ht
Installing: pyri by
Vo
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Installation is carried out in the reverse order. When installing, Prote AG.
note the following:
page 97 .

7.2.5 Vehicles with 1.9 l TDI engine

equipment required
1331- AG. Volkswagen AG d
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lksw not
Torque wrench -V.A.G byV
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1332- rised
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Spring-type clip pliers -VAS ss a ra
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5024-
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nl
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.
Removing:
-arrow B-.
7. Starter 51
spring type clip pliers -VAS 5024- .
lkswage es n
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nf
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switch.

minal 50 -2-.
AG. Volkswagen AG d
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erm
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wit
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7. Starter 53
Unscrew nut -1- from upper starter securing bolt.

AG. Volkswagen AG d
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au ra
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nl
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du
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
Unscrew earth wire securing nut -1- and place earth wire end
ion
c
-2- in direction of battery to side.

in t
or
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ate

do
priv
cum
or
Installing:
f
en
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t.
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op
Installation is carried out in the reverse order. When installing, C py
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gh ht
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Tighten threaded connections to specified torque settings cted agen
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page 97 .

7.2.6 Vehicles with 2.0 l SDI engine

AG. Volkswagen AG d
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Special tools and workshop olksw not
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equipment required rised b ara
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Torque wrench -V.A.G aut ra
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Removing:
-arrow B-.
7. Starter 55
5024- and disconnect connector -2-.
Remove securing bolt -3-.
Pull vacuum hose off -arrow-.
AG. Volkswagen AG d
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ut right side upwards off rubber mounting
Pull air filter housings aon ra
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switch.
nform
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c
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or
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do
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t.
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Cop py
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minal 50 -2-.
Unscrew earth wire from starter securing bolt -arrow-.
Unscrew starter securing bolt -arrow-.

AG. Volkswagen AG d
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V gu
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or eo
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un
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an
d
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ab

ility
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wit
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spec
t to the co
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cial p
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mer
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c
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57
AG.
7. Starter

Remove starter from vehicle downwards.
Installing:
note the following:
page 97 .
7.3 Removing and installing starter, auto

mated shift gearboxes
7.3.1 Vehicles with 1.6 l injection engine

equipment required AG. Volkswagen AG d
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Torque wrench -V.A.G ed b ara
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1331- hor eo
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Torque wrench -V.A.G ss
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un
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mer
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Removing:

5024- and remove securing bolt -2-.
Release hose -3- and pull it off the air filter housing.
-arrow-.

switch.
lkswage es n
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du
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wit
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minal 50 -2-.
h re
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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Cop py
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7. Starter 59


lkswage es n
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ility
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es, in part or in w
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Installing:
rrectness of i
note the following:

l purpos

page 97 .
nf
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AG. Volkswagen AG d
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olksw not
d by
V
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ara
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horis Electrical System - nEdition
tee 05.2005
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equipment required
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c
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7. Starter 73

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7. Starter 81


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AG. Volkswagen AG d
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7. Starter 87
Jetta 2005 , Bora 2006 AG. Volkswagen A
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7. Starter 89
AG. Volkswagen AG d
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f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
7. Starter 91

AG. Volkswagen AG d
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nl
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du
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erm
ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia

m
at
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io
Remove starter.
n
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Installing:
at
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priv
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um
for
en
note the following:
ng
t.
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op py
Tighten threaded connections to specified torque settings t. C rig
gh ht
page 97 . pyri by
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by
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7.4.6 Vehicles with 2.0 l SDI engine

equipment required
Torque wrench -V.A.G AG. Volkswagen AG d
1331- lksw
agen oes
not
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Torque wrench -V.A.G rised b ara
nte
1332- ut
ho eo
ra
s a c
Spring-type clip pliers -VAS s
ce
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5024- nl
pt
du
an
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erm
ab
ility
ot p
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
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t.
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Cop py
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rig ht
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by lksw
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Prote AG.
Removing:
-arrow B-.
7. Starter 93
5024- and disconnect connector -2-.
Pull vacuum hose off -arrow-.
AG. Volkswagen AG d
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nl
pt
du
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-arrow-.
itte
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ility
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wit
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hole
spec
es, in part or in w
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rrectness of i
l purpos

nform
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switch.
m
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ion
c
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or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
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by lksw
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minal 50 -2-.
lkswage es n
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spec
t to the co
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cial p
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form
mer
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t.
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Cop py
t. rig
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pyri by
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7. Starter 95

Remove starter.
Installing:
note the following:
page 97 .
lkswage es n
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un
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wit
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spec
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cial p
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mer
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c
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t.
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Cop py
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pyri by
Vo
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by
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Prote AG.

8 Torque settings: starter

Starters on automatic, manual gearboxes M12 75 Nm
Starter on automated shift gearboxes M10 60 Nm
Earthing wire to starter securing bolt M8 15 Nm
Wiring retainer on starter securing bolt M8 15 Nm
Positive wire to starter solenoid switch M8 15 Nm
Air filter housing to body 10 Nm
Earthing wire to automatic gearbox M8 15 Nm
AG. Volkswagen AG d
agen oes
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un
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spec
t to the co
rrectness o
cial p
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mer
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c
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Cop py
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by lksw
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Prote AG.
8. Torque settings: starter 97

9 Alternator
Caution

9.1 Fastening B+ wire to alternator
Caution
If the B+ wire is not secured with the prescribed torque the

following may occur:
Battery not charge fully.
Vehicle electrics/electronics fail completely (breakdown). agen
AG. Volkswagen AG d
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Danger of fires from sparks. by gu
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Damage to electronic components and control units due
aut
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ra
to excessive voltage. ss c
ce
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nl
pt
du
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The tightening torque for the securing nut of the B+ wire
erm
ab
ility
-arrow- an be found in the following table Tightening torques
ot p
page 145 .
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
9.2 Checking ribbed belt (poly V-belt)
at
om
ion
c
in t
r
Crank engine at vibration damper/belt pulley using a socket.

o
his
ate
do
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Fit ribbed belt (poly V-belt).

p
cum
for
en
g
Sub-surface cracks (cracks, core ruptures, cross sectional

n
t.
yi Co
breaks) Cop py
t. rig
gh ht
yri
Layer separation (top layer, draw strands) p by
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by c lksw
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chassis breakout Prote AG.
Fraying of cord strands

Flank wear (material wear, frayed flanks, flank brittleness
(glassy flanks), surface cracks)
Traces of oil and grease
Caution
It is essential to renew poly V-belt if faults are found. This will

avoid possible break-downs or operating problems.

Electrical
. Volkswage
System - Edition 05.2005
AG n AG d
agen oes
olksw not
9.3 Check alternator -C- ise
db
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ara
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Connect Vehicle Diagnosis, Testing and
s au Information System ra
c
-VAS 5051A- page 281 . s
ce
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nl
pt
du
Select guided fault finding in Vehicle Diagnosis, Testing and In
an
itte
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formation System -VAS 5051A- .
erm
ab
ility
ot p
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hole
Body
spec
es, in part or in w
t to the co
Electrical System
27 - Starter, current supply
rrectness of i
Electrical components
l purpos
C - Alternator
9.4 Alternator, 1.6 l injection engine
nf
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orm
m
atio
om
n in
9.4.1 Assembly overview
or c
thi
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cu
1 - Hexagon head collared bolt
o
m
f
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t.
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M8x108
Co
Cop py
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23 Nm
rig
gh ht
pyri by
Vo
co
2 - Hexagon head collared
by lksw
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Prote
bolts
AG.
M8x50
23 Nm
3 - Bracket
4 - Hexagon head collared nut
M8
bolts
M8x45
52 Nm
6 - Protective cap
M8
8 - Cross-head screw
M5x21
4.5 Nm
9 - Hexagon nut, flat
M8
10 - Plain washer
M5
11 - Phillips screws
M4x19
2 Nm
M4x13
9. Alternator 99
2 Nm
13 - Voltage regulator
AG. Volkswagen AG d
Removing and installing voltage regulator
ksw
agen page 142 oes n
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14 - Alternator ed
b ran
oris tee
Removing and installing
au
th alternator page 100 or
ac
ss
15 - Poly V-belt
ce
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nl
pt
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Checking page 98 .
an
itte
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erm
ab
16 - Compact bracket
ility
ot p
For alternator and air conditioner compressor
wit
, is n
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Tightening sequence page 145
hole
spec
17 - Tensioning element for poly V-belt
es, in part or in w
t to the co
M8x90
rrectness of i
23 Nm
l purpos
9.4.2 Removing and installing alternator, 1.6 l
nform
ercia
injection engine
m
at
om
ion
c
in t
or
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Caution
at
do
priv
cum
or

f
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote AG.
Locking pin -T10060 A-
Removing:

Disconnect connector of DF wiring -1- and pull protective cap

-2- off.
lkswage es n
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tho
or
Unscrew B+ wiring -arrow- off alternator. au ac
ss
ce
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nl
pt
du
Caution
an
itte
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erm
ab
ility
Mark top and direction of rotation of poly V-belt before remov
ot p
ing. When installing observe direction of rotation marked on
wit
, is n
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removal. Installing opposite to the direction of rotation leads to
hole
belt damage!
spec
es, in part or in w
t to the co
Mark direction of rotation of poly V-belt.
rrectness of i
l purpos
Release poly V-belt by turning the tensioning device with an

open-ended spanner AF 16 in -direction of arrow-.
nf
ercia
Lock tensioning element with retaining pin -T10060 A- .

orm
m
atio
Remove ribbed belt.
om
n in
or c
thi
te
sd
iva
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rp
cu
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f
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by
cted agen
Prote AG.
9. Alternator 101
AG. Volkswagen AG d
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Jetta 2005 , Bora 2006 aut
h
ra
s c
Electrical System - Edition 05.2005 s
ce
e
nl
pt
du
an
Unclip coolant hose from hose retainer -1- and remove secur
itte
y li
erm
ing nut -2-.
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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o
rm
m
atio
m
Take hose retainer together with tensioning element out of the o
n in
c
vehicle.
or
thi
te
sd
iva
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rp
cu
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m
f
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ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Remove alternator securing bolts -arrows-.
Unscrew wiring bracket -arrow- from alternator.

Remove alternator.
Installing:
note the following:
Caution
When reinstalling used ribbed belts (poly V-belts) observe

the direction of rotation marked on removal!
Ensure, before installing ribbed belt, that all ancillaries (al
ternator, air conditioner compressor) are secured tightly.
Ensure ribbed belt (poly V-belt) is seated correctly in belt
pulley when installing.

swage es n
Drive threadedbysleeves
Volk
-A- out of the alternator ot housing
gu
ara
for
approx. 4 mm ir se in -direction of arrow-.
d
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le
un
pt
an
d
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ab
ility
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is n
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ole,
spec
t to the co
Position wiring bracket -arrow- on rear of generator at 3
rrectne
o'clock.
ss
page 145 .
o
cial p
f inform
mer
Caution
atio
om
n
c
i
or
n
thi
e
page 4 .
t
sd
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pr
cum
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fo
en
ng
t.
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Co
Cop py
t. rig
gh
Start the engine and check belt running.
ht
pyri by
Vo
co lksw
by
Switch off the engine.
cted agen
Prote AG.
9.4.3 Ribbed belt routing, 1.6 l injection en

gine
Models with air conditioning system:
1- Tensioning roller
2- Ribbed belt pulley - Alternator
3- Ribbed belt pulley - Air conditioner compressor
4- Poly V-belt
5- Ribbed belt pulley - Crankshaft
9. Alternator 103
9.5 Alternator, 1.6 l FSI engine
1 - Hexagon bolt
40 Nm
2 - Washer
3 - Idler roller
4 - Washer
5 - Valve gear casing
M8 AG. Volkswagen AG d
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7 - Cross-head screw d by
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M5x21 hor eo
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4.5 Nm ss c
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M8
rm
ab
pe
ility
9 - Plain washer
ot
wit
, is n
M5
h re
hole
spec
10 - Protective cap
es, in part or in w
t to the co
M4x19
rrectness of i
2 Nm
l purpos
M4x13
nform
ercia
2 Nm
m
a
com
tion in
r
te o
thi
voltage regulator
s
iva
do
page 142
r
rp
cum
fo
14 - Alternator
en
ng
t.
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op
Removing and installing alternator page 105 C py
t. rig
gh ht
yri
15 - Poly V-belt
p by
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by c lksw
cted
Checking ribbed belt (poly V-belt) page 98
agen
Prote AG.
16 - Hexagon head collared bolts

M8x90
23 Nm
17 - Hexagon head collared bolts
M8x50
25 Nm
18 - Tensioning element
19 - Bracket
For tensioning element and air conditioner compressor
M10x50

20 Nm + 1/4 turn (90) further
21 - Spacer sleeve

FSI engine

AG. Volkswagen AG d
agen oes
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ara
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
Removing:
rrectness of i
Remove upper securing bolt of alternator -arrow-.
l purpos

Rep. Gr. 50 ; Noise insulation .
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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cu
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
9. Alternator 105
Remove wiring bracket -1- and pullAGprotective

. Volkswagencap -2- off.
agen AG do
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ua
b
ed ran
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th or
au ac
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un
pt
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d
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ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
Disconnect connector of DF wiring -1- and pull B+ wiring -2-
off alternator.
rrectness of i
Caution
l purpos
nform
ercia

m
a
com
t
belt damage!
ion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Release poly V-belt by turning the tensioning device with an Cop py
t. rig
open-ended spanner AF 16 in -direction of arrow-. gh ht
pyri by
Vo
o
by c lksw
Lock tensioning element with retaining pin -T10060 A- . Prote
cted AG.
agen
Remove ribbed belt.

Remove air conditioner compressor Heating, air condition
er; Rep. Gr. 87 ; Repair work on refrigerant circuit must be
carried out in workshops with trained personnel only (work
shop service centres for air conditioning system); Removing
and installing compressor
Remove lower securing bolt of alternator -arrow-.

Remove alternator from vehicle downwards.
Installing:
note the following:
Caution

Ensure, before installing poly V-belt, that all ancillaries
(alternator, air conditioner compressor, power assisted
steering vane pump) are secured tightly.

Drive threaded sleeves -A- out of the alternator housing for

approx. 4 mm in -direction of arrow-.

o'clock. en AG. V
olkswagen AG
ag does
lksw n
Tighten threaded connections
db
yV
o
to specified torque settingsot gua
page 145 . or
ise ran
te
h eo
ut ra
Start the enginesand
sa check belt running. c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
9.5.3 Ribbed belt routing, 1.6 l FSI engine
Models without air conditioning system:
rrectness of i
1- Ribbed belt (poly V-belt) pulley Coolant pump
l purpos
nform
3- Ribbed belt (poly V-belt) pulley Alternator

mercia
4- Poly V-belt
a
com
tion in
5- Ribbed belt (poly V-belt) pulley - Crankshaft

r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh
ht
pyri by
Vo
o
by c lksw
cted
1- Ribbed belt (poly V-belt) pulley Coolant pump
agen
Prote AG.
2- Idler roller
3- Ribbed belt (poly V-belt) pulley Alternator
5- Ribbed belt (poly V-belt) pulley Air conditioner compressor
6- Poly V-belt
7- Ribbed belt (poly V-belt) pulley - Crankshaft
9. Alternator 107
9.6 Alternator, 2.0 l FSI engine

bolts
M8x90
23 Nm
bolts
M8x50
23 Nm
3 - Transport bracket
4 - Tensioning element for poly
V-belt
5 - Compact bracket AG. Volkswagen AG d
agen oes
ksw
For alternator and air byV
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gu
ara
conditioner compressor rised
nte
ho eo
Tightening sequence aut ra
c
page 146 ss
ce
le
un
pt
an
d
itte
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bolts
rm
ab
pe
M10x45
ility
ot
wit
, is n
52 Nm
h re
hole
7 - Protective cap
spec
es, in part or in w
t to the co
M8
rrectness of i
M5x21
l purpos
4.5 Nm
nform
ercia

M8
m
a
com
tion in
11 - Plain washer
r
te o
thi
M5
s
iva
do
r
rp
um
fo
en
ng
t.
M4x19
yi Co
Cop py
2 Nm ht. rig
rig ht
py by
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by c lksw
cted agen
Prote AG.
M4x13
2 Nm
Removing and installing voltage regulator page 142
15 - Alternator
Removing and installing alternator page 109
16 - Poly V-belt
Checking page 98 .

9.6.2 Removing and installing alternator, 2,0 l

FSI engine
Caution

Special tools and workshop AG. Volkswagen AG d

agen oes
ksw
equipment required by
Vol not
gu
d ara
ise nte
Torque wrench -V.A.G hor eo
1331- aut ra
ss c
ce
e
Locking pin -T10060- or

nl
pt
du
locking pin -T10060 A-
an
itte
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erm
ab
ility
ot p
5024 A-
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing:
9. Alternator 109
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
ss c
ce
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un
pt
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
clip pliers -VAS 5024 A- .

n in
r
te o
thi

s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

hose -1- off.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
s au ra
c
s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
-arrow-.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5024 A- .
9. Alternator 111
Separate connector -arrow- on rear of air filter housing.

Remove upper intake manifold.

-2- off.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
Unscrew B+ wiring -arrow- off alternator.
ot
wit
, is n
h re
hole
Caution
spec
es, in part or in w
t to the co
rrectness of i
belt damage!
l purpos
Mark direction of rotation of poly V-belt. nform

mercia
a
com
tio

n in
r

te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


Remove ribbed belt.
Remove securing bolts of tensioning element -arrows-.

Take tensioning element together with lifting eye -1- out of the
vehicle.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
e
nl
pt
du
an
Unscrew wiring bracket -arrow- from alternator.

itte
y li
erm
ab
Take alternator out of the vehicle.

ility
ot p
wit
, is n
Installing:
h re
hole
spec

es, in part or in w
note the following:

t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
9. Alternator 113


o'clock.
page 145 .
Caution

the direction of rotation marked on removal! wage
e ks s no
Vol t gu
Ensure, before installing ribbed belt, that all ancillaries
db
y (al ara
ternator, air conditioner compressor) are secured rise tightly. nte
tho eo
au ra
Ensure ribbed belt (poly V-belt) is seatedsscorrectly in belt c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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page 145 .
wit
, is n
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Caution
es, in part or in w
t to the co
page 4 .
rrectness of i
l purpos

nform
ercia

m
at
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ion
c
in t
r
9.6.3 Ribbed belt routing, 2,0 l FSI engine

o
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ate
do
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p
cum
for
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ng
t.
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Cop py
t. rig
2- Ribbed belt pulley - Alternator opyri
gh by
Vo
ht
c
3- Poly V-belt
by lksw
cted agen
Prote AG.

AG. VolkswageElectrical
n AG d System - Edition 05.2005
agen oes
olksw not
y V gu
Models with air conditioning system: rised b ara
nte
ho eo
1- Tensioning roller aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
4- Poly V-belt
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
9.7 Alternator, 2.0 l FSI turbo engine
l purpos
nform
mercia
a
com
tion in
r
te o
thi
bolts
s
iva
do
M8x45
r
rp
cum
fo
23 Nm
en
ng
t.
yi Co
op py
2 - Hexagon head collared . C rig
ht ht
bolts
rig by
copy Vo
by lksw
M8x90 Prote
cted AG.
agen
23 Nm
3 - Compact bracket
For alternator and air
conditioner compressor
Tightening sequence
page 146
bolts
M10x45
45 Nm
5 - Protective cap
M8
M5x21
4.5 Nm
M8
9 - Plain washer
M5
M4x19
2 Nm
M4x13
2 Nm
9. Alternator 115
13 - Alternator
14 - Poly V-belt
Checking page 98 .
15 - Tensioning element for poly V-belt

turbo FSI engine
Caution


equipment required
1331-
Locking pin -T10060- or
locking pin -T10060 A-
5024 A-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
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un
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an
d
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erm
ab
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wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
r
fo
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Removing:
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
Loosen spring-type clips -1- using spring type clip pliers -VAS s
ce
le
5024 A- .
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
9. Alternator 117
Note
All hoses of the charge air system are secured with hose clips
or with quick release couplings. When using quick release
couplings the following points must be observed:
Unlock connection by pulling the securing clamp -arrow-.
Pull hose/tube off without assistance of tools.
Disconnect quick release coupling -arrow-.
Loosen spring-type clip -arrow- using spring type clip pliers -

VAS 5024 A- .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole

spec
es, in part or in w
Take hose out of the vehicle.

t to the co
Remove connecting pipe between charge air cooler and tur

bocharger.
rrectness of i
l purpos
Caution

nform
ercia

m
at

om
io
belt damage!
n
c
in t
or
his
ate
do
priv

um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Release poly V-belt by turning the tensioning element with an

open jaw spanner AF 16 in -direction of arrow- and lock ten n AG. Volkswagen A
sioning element with retaining pin -T10060 A- . olks
wage
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Remove ribbed belt. db ara
rise nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
Loosen threaded connections of coolant pipe -arrows-.
rrectness of i
Note
l purpos
The coolant pipe can remain installed. To take out the alternator
it must be loosened.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

-2- off.
9. Alternator 119
AG. Volkswagen AG d
agen oes
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Unscrew wiring bracket -arrow- from alternator. by Vol not
gu
d ara
ise nte
Take alternator out of the vehicle. thor eo
au ra
c
Installing: ss
ce
le
un
pt
an
d
itte
y li
note the following:
rm
ab
pe
ility
ot
wit
Caution
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
a
com
ti
on in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

o'clock.

Note
Fit hose/tube without assistance of tools. agen
AG. Volkswagen AG d
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olksw not
Check for secure fit of the lugs -arrow-. ed byV gu
ara
ris nte
ho eo
ut
Tighten threaded connections to specified torque
ss a settings ra
c
page 145 .
ce
e
nl
pt
du
an
itte
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Caution
erm
ab
ility
ot p
wit
, is n
h re
page 4 .
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
9.7.3 Ribbed belt routing, 2.0 l turbo engine
nform
ercia

m
at
om
io
n
c
in t
or
his
e

at
do
priv
c
3- Poly V-belt
um
for
en
ng
t.
yi
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

4- Poly V-belt
9. Alternator 121
9.8 Alternator 2.5 l injection engine
1 - Compact bracket
wage
e ks s no
Vol t gu
2 - Multi-point socket ed head bolt
by ara
M8x60 oris nte
eo
th
25 Nm au ra
c
ss
ce
e
nl
3 - Multi-point socket head bolt
pt
du
an
M8x110
itte
y li
erm
ab
25 Nm
ility
ot p
wit
4 - Hexagon socket head bolt
, is n
h re
M8x30
hole
spec
25 Nm
es, in part or in w
t to the co
Qty. 4
5 - Protective cap for alternator
rrectness of i
6 - Phillips screws
l purpos
M4x20
2 Nm
nf
ercia
7 - Protective cap for carbon

rm
m
brushes
atio
om
n in
c
or
thi
e

t
sd
iva
voltage regulator
r
rp
cu
o
page 142
f
en
ng
t.
yi Co
op
9 - Alternator C py
ht. rig
rig ht
Removing and installing py by
o Vo
alternator page 127
by c lksw
cted agen
Prote AG.
10 - Poly V-belt
Checking page 98 .
bolts M8x90
25 Nm
Qty. 2
9.8.2 Removing and installing alternator, 2.5l

engine
Caution

Removing:

AG. Volkswagen AG d
agen oes
olksw not
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ise nte
or eo
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Disconnect the battery page 29 . aut ra
ss c
ce
le
Take the engine cover off upwards and forwards.

un
pt
an
d
itte
Bring lock carrier into service position General body repairs,
y li
erm
ab
exterior; Rep. Gr. 50 ; Lock carrier service position
ility
ot p
wit
Take off poly V-belt Rep. Gr. 13
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f
inform
-2- off.
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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9. Alternator 123
lkswage es n
o ot g
byV ua
d ran
ir se
Jetta 2005th , Bora 2006
o tee
or
u
Electrical
ss System - Edition 05.2005
a ac
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
Caution
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
belt damage!
rrectness of i
Remove upper and lower idler roller and tensioning roller for
l purpos
alternator poly V-belt, and coolant pump Rep. Gr. 13
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
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ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Unscrew wiring bracket from alternator -arrow-.

Take alternator out upwards.
Installing:
note the following:
Caution


approx. 4 mm in direction of arrow.

Position wiring bracket -arrow- on rear of wgenerator

agen
AG. Voat 9agen AG doe
lksw
o'clock. y Volks s no
t gu
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Tighten threaded connections htorisspecified torque settings nte
t o e
page 145 . sa
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ac
s
ce
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nl
pt
du
Caution
an
itte
y li
erm
ab
ility
ot p
page 4 .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
9.8.3 Ribbed belt routing, 2.5l engine

nf
ercia
orm
1- Upper idler roller
m
atio
om
n in
c
2- Belt pulley - Alternator

or
thi
te
sd
a
3- Lower idler roller

iv
o
r
rp
cu
o
m
4- Poly V-belt for alternator and coolant pump
f
en
ng
t.
yi Co
op
5- Belt pulley - Air conditioner compressor C py
t. rig
gh ht
yri
6- Poly V-belt for air conditioner compressor
p by
co Vo
by lksw
cted agen
7- Belt pulley - Crankshaft
Prote AG.
8- Tensioning roller for air conditioner compressor poly V-belt

9- Tensioning roller for alternator poly V-belt and coolant pump
10 - Belt pulley - Coolant pump
9. Alternator 125
9.9 Alternator, 1.9 l TDI engine

AG. Volkswagen AG d
agen oes
ksw
9.9.1 Assembly overview ol not
y V gu
d b ara
rise nte
tho eo
au ra
c
1 - Hexagon head collared ss
ce
le
bolts
un
pt
an
d
itte
M8x45
y li
erm
ab
20 Nm
ility
ot p
wit
is n
h re
V-belt
ole,
spec
t to the co
bolts
M8x90
rrectne
20 Nm
4 - Compact bracket
ss
o
cial p
f
inform
mer
Tightening sequence
atio
page 148
om
n
c
i
or
n
thi
te
bolts
sd
iva
o
pr
c
M10x65
um
r
fo
en
ng
40 Nm
t.
yi Co
Cop py
t. rig
6 - Hexagon head collared yri
gh by
ht
bolts cop Vo
by lksw
cted agen
M10x45 Prote AG.
40 Nm
7 - Hexagon bolt with washer
and threaded piece
M4x20, M4x15
2 Nm
8 - Protective cap for alternator
9 - Phillips screws
M4x20
2 Nm
10 - Protective cap for carbon brushes
12 - Alternator
13 - Poly V-belt
Checking page 98 .


TDI engine
Caution

Removing:
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co

-arrow B-.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
9. Alternator 127
Note
Unlock connection by pulling the securing clamp -arrow-.
Pull hose/tube off without assistance of tools.
Disconnect connectors -1-.

Unclip fuel hoses -2- and take charge air hose out.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
Pull vacuum hose -1- off.
ab
ility
ot p
Disconnect connector -2-.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
Unbolt securing bolt -arrow-.

at
om
ion
c

in t
or
his
e

at
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Unscrew charge air pipe securing bolt -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Disconnect connector of charge air pipe -arrow-.
hole
spec
Take charge air pipe out upwards.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e

t
sd
iva
-2- off.
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Pull fuel filter off the retainer and place to side (fuel hoses re
main connected).
Caution

belt damage!
9. Alternator 129


Remove ribbed belt.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
Unscrew wiring bracket from alternator -arrow-.

rp
cum
fo
en
ng
Remove alternator.
t.
yi Co
Cop py
t. rig
Installing: opyri
gh by
Vo
ht
c
by lksw
cted agen
Prote
note the following:
AG.
Caution




o'clock.
Note
Fit hose/tube without assistance of tools.
G. Volkswage nA n AG d
wage oes
Check for secure fit of they Vlugs
olks -arrow-. not
gu
b ara
ed nte
oris eo
Tighten threadedauconnections
th to specified torque settings ra
page 145 . ss c
ce
e
nl
pt
du
an
itte
Caution
y li
erm
ab
ility
ot p

wit
, is n
page 4 .
h re
hole
spec
es, in part or in w
t to the co

rrectness of i

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
9. Alternator 131
Electrical System - Edition 05.2005 agen
AG. Volkswagen AG d
oes
olksw not
byV gu
9.9.3 Ribbed belt routing, 1.9 l TDI engine d ara
ise nte
or eo
h
aut ra
Models without air conditioning system: ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
3- Poly V-belt
wit
is n
h re
4- Ribbed belt pulley - Crankshaft ole,
spec
t to the co
rrectnes
s o
cial p
f in
form
mer
atio
om
n
c
i
or
n thi
te
sd
a
4- Poly V-belt
iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

9.10 Alternator, 2,0 l TDI engine

bolts
M8x45
20 Nm
V-belt
bolts
M8x90
20 Nm
4 - Compact bracket
Tightening sequence agen
AG. Volkswagen AG d
oes
page 148 olksw not
V gu
d by ara
e
5 - Hexagon head collared horis nte
eo
bolts s aut ra
c
s
M10x65
ce
e
nl
pt
du
40 Nm
an
itte
y li
erm
ab
ility
ot p
bolts
wit
, is n
M10x45
h re
hole
spec
40 Nm
es, in part or in w
t to the co
7 - Phillips screws
M4x20
2 Nm
rrectness of i
8 - Protective cap
l purpos
nform
ercia

voltage regulator
m
at
om
page 142
ion
c
in t
or
10 - Alternator
his
ate
do
riv

p
cum
for
11 - Poly V-belt
en
ng
t.
yi Co
op
Checking page 98 . C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
9.10.2 Removing and installing alternator, 2,0 l
TDI engine
Caution

9. Alternator 133
Removing:
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io

n
c
in t
or
his
e

at
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Pull vacuum hoses off -arrow-.

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AG n AG d
agen oes
olksw not
Unbolt securing bolts -arrow-. db
yV gu
ara
rise nte
tho eo
s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
-2- off.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
Pull fuel filter off the retainer and place to side (fuel hoses re
main connected).
Caution

belt damage!

9. Alternator 135

Remove ribbed belt.
Unscrew wiring bracket s-arrow-

wage
n AGfrom
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wagen AG
does
k not
Vol gu
Remove alternator.
se
db
y ara
nte
ri
Installing: utho eo
ra
a c
ss
ce
e
nl
pt
du
note the following:

an
itte
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erm
ab
ility
Caution
ot p
wit
, is n
h re

hole
spec

es, in part or in w
t to the co

rrectness of i

l purpos
nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


o'clock.
page 145 .
Caution

page 4 .

9.10.3 Ribbed belt routing, 2,0 l TDI engine

2- Ribbed belt pulley - Alternator n AG. Volkswagen AG do
lkswage es n
o ot g
3- Poly V-belt d byV ua
ran
ir se tee
autho
or
ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2- Ribbed belt pulley - Alternator rrectness of i

l purpos
4- Poly V-belt
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
9.11 Removing and installing ribbed belt

p
cum
for
(poly V-belt) pulley on alternator

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
9.11.1 Removing and installing a ribbed belt
c by lksw
cted agen
Prote AG.
(poly V-belt) pulley with no freewheel
9. Alternator 137
Socket -VAS 3310-
AG. Volkswagen AG d
agen oes
olksw not
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aut ra
Removing: ss c
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nl
pt
du
Take off alternator page 98 .
an
itte
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erm
Fit alternator in a vice on fitting points.
ab
ility
ot p
Use socket -VAS 3310- to remove ribbed belt (poly V-belt)
wit
, is n
pulley securing nut from alternator shaft.
h re
hole
spec
Installing:
es, in part or in w
t to the co
rrectness of i
page 145 .
l purpos
nform
mercia
at
om
ion
c
in t
9.11.2 Removing and installing a ribbed belt

or
his
ate
(poly V-belt) pulley with freewheel, man

do
priv
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ufacturer: Bosch
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Prote AG.

Adapter -VAS 3400-
Removing:
Take protective cap off ribbed belt (poly V-belt) pulley with
freewheel.
AG. Volkswagen AG d
agen oes
Note olksw not
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The thread on the alternator shaft isauat left-hand thread, i.e. turn
ho eo
ra
to right when loosening and to leftsswhen tightening the threaded c
joint.
ce
le
un
pt
an
d
itte
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Fit adapter -VAS 3400- in the ribbed belt (poly V-belt) pulley
rm
ab
pe
ility
with a freewheel of the alternator with a ring spanner AF 17.

ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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te o
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by
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cted agen
Prote AG.
9. Alternator
Insert a socket M10 -1- in the alternator shaft.

Loosen threaded joint by turning to right and counter-hold with
ring spanner.
Hold the ribbed belt (poly V-belt) pulley with a freewheel with
the hand and turn the drive shaft of the alternator until the rib
bed belt (poly V-belt) pulley with a freewheel can be taken off.
Installing:
note the following:
At first screw the ribbed belt (poly V-belt) pulley with a free
wheel on the drive shaft of the alternator by hand to limit stop.
The torque wrench -V.A.G 1332- must be rearranged before in
stalling the ribbed belt (poly V-belt) pulley with a freewheel as
follows:
Release socket -1- and pull off grip -2-. agen

AG. Volkswagen AG d
oes
olksw not
V
Turn the torque wrench grip -2- through
ed by 180 degrees and re gu
ara
insert socket drive. horis nte
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Set torque wrench directions of rotation on socket to left.
s c
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du
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
Insert a socket M10 -1- in the alternator shaft.

rrectness of i
Counter-hold adapter -VAS 3400- with ring spanner, AF 17.

Tighten the ribbed belt (poly V-belt) pulley with a freewheel by
l purpos
turning the alternator drive shaft to left using torque wrench -

V.A.G 1332- .
nf
ercia
or

m
m
atio
page 145 .
om
n in
or c
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Prote AG.

9.11.3 Removing and installing a ribbed belt (poly V-belt) pulley with freewheel,
manufacturer: Valeo
wage es n
Special tools and yV
olworkshop
ks ot g
ua
equipment isrequired
ed
b ran
or tee
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Adapter
aut
-VAS 3400- or
ac
ss
ce
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un
pt
1332-
an
d
itte
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ab
TORX key -V.A.G 1603/1-
ility
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spec
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rrectness o
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f inform
mer
atio
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c
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te
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pr
cum
r
fo
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ng
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing:
Take protective cap off ribbed belt (poly V-belt) pulley with
freewheel.
Note
The thread on the alternator shaft is a left-hand thread, i.e. turn

to right when loosening and to left when tightening the threaded
joint.
Fit adapter -VAS 3400- in the ribbed belt (poly V-belt) pulley
with a freewheel of the alternator with a ring spanner AF 17.
9. Alternator 141
Fit TORX key -V.A.G 1603/1- into alternator shaft.

Loosen threaded joint by turning to right and counter-hold with
ring spanner.
Hold the ribbed belt (poly V-belt) pulley with a freewheel with
the hand and turn the drive shaft of the alternator until the rib
bed belt (poly V-belt) pulley with a freewheel can be taken off.
Installing:
note the following:
At first screw the ribbed belt (poly V-belt) pulley with a free
wheel on the drive shaft of the alternator by hand to limit stop.
The torque wrench -V.A.G 1332- must be rearranged before in
stalling the ribbed belt (poly V-belt) pulley with a freewheel as
follows:
Release socket -1- and pull off grip -2-.

Turn the torque wrench grip -2- through 180 degrees and re
insert socket drive.
Set torque wrench direction of rotation on socket to left.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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ss
Fit TORX key -V.A.G 1603/1- into alternator shaft.
ce
e
nl
pt
du
an
Counter-hold adapter -VAS 3400- with ring spanner, AF 17.

itte
y li
erm
ab
Tighten the ribbed belt (poly V-belt) pulley with a freewheel by

ility
ot p
turning the alternator drive shaft to left using torque wrench -

wit
, is n
V.A.G 1332- .
h re
hole
spec

es, in part or in w
page 145 .
t to the co
rrectness of i
l purpos
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9.12 Voltage regulator for alternator

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9.12.1 Removing and installing voltage regula
cop Vo
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tor, manufacturer: Bosch
Prote AG.

Torque screwdriver -V.A.G 1624-
Removing:
Remove alternator.
Remove securing bolt and nuts -arrows- and take protective
cap off alternator.
wage es n
Remove securingy Vbolts olks
for voltage regulator -arrows-.
ot g
ua
b
ed ran
Remove voltage thoris
regulator from alternator. tee
u or
a ac
Installing: ss
ce
le
un
pt
Install in reverse order of removal.

an
d
itte
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erm
ab
ility
page 145 .
ot p
wit
is n
h re
ole,
spec
t to the co
9.12.2 Removing and installing voltage regula

rrectne
tor, manufacturer: Valeo

ss

o
cial p
f inform
Torque wrench -V.A.G 1783/-

mer
atio
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c
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cted agen
Prote AG.
9. Alternator 143
Removing:
Remove alternator.
Remove spring clips -arrows- and take protective cap off al
ternator.
Remove securing bolts for voltage regulator -arrows-.

Remove voltage regulator from alternator.
Installing:
note the following:
AG. Volkswagen AG d
agen
Release locking lugs -arrow- andVpull
olks protective cap off voltage
w oes
not
gu
regulator. se
d by ara
n i tee
or
Push voltage regulator acarbon
ut
h
brushes in housing of voltage or
ac
regulator and place voltage
ss
regulator in alternator.
ce
le
un
pt

an
d
itte
page 145 .
y li
rm
ab
pe
ility
ot
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spec
es, in part or in w
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Push protective cap into guides -arrows- until it audibly en

rrectness of i
gages.
l purpos
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mercia
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te o
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Prote AG.

10 Torque settings: alternator
10.1 General torque settings for all vehicles

B+ wire to alternator M8 15 Nm
Cable holder to alternator M5 3,2 Nm
Voltage regulator to alternator M4 2 Nm
Protective cap to alternator M5 4.5 Nm
Poly V-belt pulley with freewheel to alternator M10 80 Nm
Poly V-belt pulley without freewheel to alternator M10 65 Nm
10.2 1.6 l injection engine and 2.0 l FSI en

gine
Caution
In order to avoid damage to cylinder block and compact brack

et, you must respect the tightening sequence for the compact
bracket.
10.2.1 Torque settings

AG. Volkswagen AG d
Alternator to compact M8 23 Nm lksw
agen oes
not
bracket by
Vo gu
ara
ed
nte
Tensioning element to com M8x50 23 Nm horis
eo
pact bracket aut ra
ss c
Compact bracket to cylin M10x45 52 Nm
ce
e
nl
pt
du
der block
an
itte
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erm
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ility
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
en
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t.
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Cop py
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Prote AG.
10. Torque settings: alternator 145

AG. Volkswagen AG d
Electrical System - Edition 05.2005 lksw
agen oes
not
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10.2.2 Tightening sequence for compact brack ris nte
ho eo
ut ra
et, models with air conditioning system s a c
s
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nl
pt
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Tightening sequence for compact bracket to cylinder block
an
itte
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erm
ab
Procedure
ility
ot p
Place compact bracket on cylinder block.
wit
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
Before tightening to specified torque setting, screw in all bolts by
hand.
rrectness of i
l purpos
Tighten securing bolts of compact bracket in following se

quence:
nform
ercia
A - Hexagon head collared bolt, M10x45, 52 Nm, locating hole

m
at
B - Hexagon head collared bolt, M10x45, 52 Nm
om
ion
c
in t
C - Hexagon head collared bolt, M10x45, 52 Nm
or
his
ate
do
riv
D - Hexagon head collared bolt, M10x45, 52 Nm

p
cum
for
E - Hexagon head collared bolt, M10x45, 52 Nm
en
ng
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op
F - Hexagon head collared bolt, M10x45, 52 Nm
C py
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10.3 2.0 l FSI turbo engine
cted agen
Prote AG.
Caution
In order to avoid damage to cylinder block and compact brack

et, you must respect the tightening sequence for the compact
bracket.

Alternator to compact M8x90 23 Nm
bracket
Tensioning element to com M8x90 23 Nm
pact bracket
der block
Air conditioner compressor M8x100 23 Nm
to compact bracket

10.3.2 Tightening sequence for compact brack

et, models with air conditioning system
Procedure
Note
Before tightening to specified torque setting, screw in all bolts by

hand.

quence:
A - Cylinder collar screw, M10x45, 40 Nm, locating hole
B - Cylinder collar screw, M10x45, 40 Nm
C - Cylinder collar screw, M10x45, 40 Nm
D - Cylinder collar screw, M10x45, 40 Nm
E - Cylinder collar screw, M10x45, 40 Nm
F - Cylinder collar screw, M10x45, 40 Nm
10.4 1.9 l and 2.0 l TDI engine

AG. Volkswagen AG d
agen oes
ksw
Caution byV
ol not
gu
d ara
ise nte
or eo
In order to avoid damage to cylinder block
aut
h and compact brack ra
et, you must respect the tightenings sequence for the compact
s c
bracket. ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
h re

ole,
spec
Alternator to compact bracket M8x90 20 Nm

t to the co
Tensioning element to compact bracket M8 20 Nm

Compact bracket to cylinder block M10 40 Nm
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
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fo
en
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t.
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Cop py
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rig ht
py by
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by lksw
cted agen
Prote AG.
10. Torque settings: alternator 147

10.4.2 Tightening sequence for compact brack

et
Procedure
Note
Observe dowel sleeve between compact bracket and cylinder

block.
Before tightening to specified torque setting, screw in all bolts
by hand.

quence:
A - Hexagon head collared bolt, M10x65, 40 Nm
B - Hexagon head collared bolt, M10x45, 40 Nm
C - Hexagon head collared bolt, M10x45, 40 Nm
D - Hexagon head collared bolt, M10x45, 40 Nm
E - Hexagon head collared bolt, M10x65, 40 Nm
F - Hexagon head collared bolt, M10x65, with dowel sleeves 40
Nm
10.5 2.5 l injection engine
10.5.1 Torque settings olkswage es n
ot g
byV ua
ed ran
oris tee
th or
u
Alternator to compact M8x90 25 Nm ss
a ac
bracket
ce
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nl
pt
du
an
Tensioning element to com M8x50 23 Nm

itte
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pact bracket
erm
ab
ility
ot p

wit
, is n
der block
h re
hole
spec
es, in part or in w
t to the co
Note
Observe dowel sleeve between compact bracket and cylinder

rrectness of i
block.
l purpos
For the compact bracket no tightening torque must be ob

served.
nf
ercia
orm
m
atio
om
n in
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thi
te
sd
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Prote AG.

11 Cruise control system (CCS)

General description:
The functions of the cruise control system are controlled by the
engine control unit.
There are no additional components, apart from the switch for
CCS -E45- , which is integrated into the turn signal switch.
Removing and installing switch for CCS -E45- (turn signal
switch) page 224 .
You can activate and deactivate the cruise control system
page 149 .
Fault detection and fault display:
Faults on the CCS are output via the engine control unit.
For fault finding, use the vehicle diagnosis, testing and informa
tion system -VAS 5051A- in guided fault finding mode.
11.1 Activating and deactivating cruise Vol
kswcon
age es n
ot g
trol system
y ua
db ran
ise tee
or h
ut or
Connect Vehicle Diagnosis, Testing and
ss Information
a System ac
-VAS 5051A- page 281 .
ce
e
nl
pt
du
an
itte
y li
Select guided fault finding in Vehicle Diagnosis, Testing and
erm
ab
Information System -VAS 5051A- .
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Drive
t to the co
Engine code
01 - On Board Diagnostic capable systems
rrectness of i
Engine control and/or direct diesel injection and pre-glow sys
l purpos
tem
Function
nform
ercia
Activating and deactivating cruise control system

m
at
om
ion
c
in t
or
his
ate
do
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cum
for
en
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t.
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Cop py
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Prote AG.
11. Cruise control system (CCS) 149

90 Instruments, GCI
1 Dash panel insert
Integrated in the dash panel insert are the following components:
Control unit with display in dash panel insert -J285-
Immobilizer control unit -J362-
Speedometer
Rev counter
Fuel gauge
Coolant temperature gauge
Multi-function display
Warning lamps, page 152
To provide acoustic support to somen AofG.the
Volkvisual
swagendisplays,
AG do
the
dash panel features a warning
olksbuzzer,
wage which is actuated es nby the
o
control unit. db
yV t gu
ar
e an
ris tee
All warning lamps feature
tho LEDs. No provision has been made for or
au
repair of the dashs panel insert. In the event of defects, the dash
s ac
panel insert is renewed as a unit page 150 .
ce
e
nl
pt
du
an
The data bus diagnostic interface -J533- (Gateway) is an individ

itte
y li
erm
ual control unit option and not, as on other vehicles, part of the
ab
ility
dash panel insert page 294 .

ot p
wit
, is n

h re
hole
spec
The dash panel insert is equipped with self-diagnosis which

es, in part or in w
makes fault finding easier.

t to the co
rrectness of i
1.1 Renewing dash panel insert

l purpos
The work sequence Renewing dash panel insert consists of the

following work:
nf
ercia
orm
m
If a new dash panel insert has to be installed in the vehicle,

atio
m
the dash panel insert control unit has to be adapted to the dif
o
n in
c
ferent vehicle equipment and the respective country variant.

or
thi
te
sd
iva
To adapt the integrated immobilizer to the engine control unit,

o
r
rp
cu
the data of the engine control unit must be stored in the ex

o
m
f
en
ng
change dash panel insert.

t.
yi Co
Cop py
After installing a new dash panel insert, perform adaption of ht. rig
rig ht
all vehicle keys. py by
co Vo
by lksw
cted agen
Special tools and workshop equipment required Prote AG.
150 Rep. Gr.90 - Instruments, GCI

Vehicle Diagnosis, Testing and Information System -VAS

5051A-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
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ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
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Diagnosis lead -VAS 5051/6A-
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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Select guided fault finding in Vehicle Diagnosis, Testing and Cop py
ht. rig
rig ht
py by
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by lksw
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Prote
AG.
Body
Electrical System
Dash panel insert
Dash panel insert functions
Adapting/renewing dash panel insert
1.2 Removing and installing dash panel in

sert
Note
Before removing the dash panel insert, the work procedure Re

newing dash panel insert should always be carried out in order
that the data stored in the control unit can be interrogated
page 150 .
Removing:
ignition key.
Remove steering wheel General body repairs, interior; Rep.
Gr. 69 ; Airbag; Removing and installing steering wheel .
1. Dash panel insert 151

Remove the upper part of the steering column trim General

body repairs, interior; Rep. Gr. 68 ; Compartments, covers
and trim; Removing and installing steering column switch trim .
Remove securing bolts -arrows- for 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:
1.3 Description of reverse side of dash pan

el insert olks
wage
es n
o
yV t gu
db ara
rise nte
tho eo
Note au ra
c
ss
ce
le
The dash panel insert must not be dismantled. In the event of

un
pt
an
d
defects, the dash panel insert is renewed as a unit.

itte
y li
erm
ab
ility
ot p
1- 36-pin connector
wit
is n
h re
2- Warning buzzer
ole,
spec
t to the co
1.4 Warning lamp symbols in dash panel in
sert
rrectne
Note
ss o
cial p
f i
The warning lamps on the dash panel insert depend on the vehi
nform
cle's equipment, country and engine type.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1 - Electric On Board Diagno

sis (EOBD)
2 - Engine malfunction (EPC)
Warning lamp is fitted AG. Volkswagen AG d
agen
only on vehicles with olksw
oes
not
petrol engine. byV gu
ara
ed
ris nte
o eo
3 - Immobilizer aut
h
ra
ss c
4 - Battery charge
ce
le
un
pt
an
d
5 - Bulb failure
itte
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rm
ab
pe
6 - Rear fog lights
ility
ot
wit
, is n
7 - Low coolant level
h re
hole
spec
8 - Brake pad wear es, in part or in w
t to the co
9 - Washer fluid level
10 - Fuel reserve
rrectness of i
11 - Airbag display
l purpos
12 - Seat belt
13 - Anti-locking brake system
nform
ercia
(ABS)
m
a
14 - Electronic stabilisation
com
tion in
programme (ESP)
r
te o
thi
s
15 - Brake fault/handbrake
iva
do
r
rp
cum
16 - Cruise control system
fo
en
ng
(CCS)
t.
yi Co
Cop py
. rig
17 - Daylight
ht ht
rig by
copy Vo
lksw
18 - Tyre pressure monitor
by
cted agen
Prote AG.
19 - Water in fuel
20 - Rear seat backrest lock
21 - Shift Lock
Warning lamp exists only on vehicles with automatic gearbox
22 - Oil level
23 - Bonnet open
24 - Door open
25 - Oil pressure
26 - Main beam
27 - Steering heating
28 - Trailer turn signals
29 - Glow plug system
Warning lamp is fitted only on vehicles with diesel engine.
30 - Tank filler cap
31 - Exhaust filter
32 - Electronic steering (EPS-Electronic Power Steering)
1. Dash panel insert 153

2 Service interval display
2.1 Resetting service interval display

Maintenance ; Booklet 20.1
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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f
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

92 Windscreen wash/wipe system

1 Windscreen wiper system
Caution

Note
Additional information:
Operating instructions
The wiper motor control unit -J400- and the wiper motor -V- are
joined together as one unit.
To remove the wiper blades, the wiper arms should be placed in
the service/winter position. Theservice/winter position is acti
vated within 10 seconds after ignition is switched off by pressing
windscreen wiper lever in tip wipee Operating instructions for
vehicle . olks
wag es n
o V t gu
by ara
Fault detection and fault
ris display:
ed nte
tho eo
The onboard supply au control unit -J519- is equipped with self-di ra
c
ss
agnosis, which is designed to ease fault finding.
ce
le
un
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1.1 Deactivating APP function of wiper mo

spec
es, in part or in w
tors
t to the co

rrectness of i

5051A-
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tion in
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Prote AG.
1. Windscreen wiper system 155

Diagnosis lead -VAS 5051/6A-
AG. Volkswagen AG d
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wit
is n
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The windscreen wiper system is equipped with an APP function
spec
(alternating park position system).
t to the co
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.
rrectne
To fit the crank arm on the wiper motor, it is necessary for the
motor to be in the lowest park position. To ensure this position is
ss
reached, the APP function must be deactivated (code wiper motor
o
cial p
f
control unit -J400- ).
inform
mer
atio
m
Note
o
n
c
i
or
n thi
te
The APP function cannot be activated. sd

iva
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fo
After 100 cycles of wiper movement, the APP function is acti

en
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t.
vated automatically. This applies to wiper motors on which the
yi Co
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APP function has been deactivated and also to new wiper mo
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Prote AG.
Body
Electrical System
Onboard supply control unit
Onboard supply control unit functions
Control unit functions for wiper electronics
1.2 Removing and installing the windscreen

wiper system
Caution

156 Rep. Gr.92 - Windscreen wash/wipe system


equipment required
1331-
Puller -T10130-
Removal lever -80-200-
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1.2.1 Removing windscreen wiper system

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Deactivating APP function page 155 .

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Allow wiper to move to park position and then switch ignition

h re
hole
off.
spec
es, in part or in w

t to the co
Note
rrectness of i
l purpos
To remove the wiper frame with rods and the wiper motor, wiper
arms, plenum chamber cover and air duct cover must be re
moved.
nform
mercia
at
om
ion
c
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or
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ate
do
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Prote AG.

1.2.2 Removing wiper arm

Lever off the protective cap -arrows- using a screwdriver.
Loosen the hexagon nut -arrows-, without removing it com

pletely.
Position legs of puller -T10130- -2- under wiper arm-4- as wagen AG. Volkswagen AG doe
shown in the figure. yV
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Turn thrust bolt -1- of puller -T10130- clockwisethountil
ris it comes nte
e or
into contact with the wiper shaft. The hexagon au nut -3- previ ac
ss
ously loosened on the wiper arm serves as a means of centring
ce
e
and guiding the thrust bolt -1-.

nl
pt
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an
itte
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Turn thrust bolt -1- of puller -T10130- clockwise using 6 mm
erm
ab
spanner until wiper arm -4- is released from the shaft.
ility
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spec
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1.2.3 Removing plenum chamber cover

rrectness of i
Unclip plenum chamber cover -1-, starting from side, off top of
windscreen frame -arrow-.
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
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t.
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Cop py
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rig ht
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by lksw
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Prote AG.

1.2.4 Removing air cowling

Remove securing screws -1- and securing nut -2- from air
cowling -3-.
Take air cowling -3- out of vehicle.
1.2.5 Removing wiper frame with linkage and

wiper motor
Unscrew securing bolts -arrows- and pull wiper frame -2- for
wards out of vehicle.
1.2.6 Removing wiper motor out of wiper

frame G. Volkswagen nA AG do
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Lever linkage -arrow- ball Vol head -1- using release leverot gu
ks sn
by
-80-200- off crankriarm
se
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spec
Remove securing nut -1-.

t to the co
Pull crank -2- off wiper motor shaft.

Unscrew securing bolts -arrows- and remove wiper motor with
rrectne
control unit from wiper frame.

ss o
cial p
f inform
mer
atio
om
n
c
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or
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te
sd
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t.
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Cop py
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pyri by
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Prote AG.

1.2.7 Installing wiper motor in wiper frame

Insert wiper motor with control unit in wiper frame and secure
it in place with the securing bolts -arrows-.
page 178 .
e n AG. Volkswagen AG
Place crank arm of motor ks-1-
wagon shaft of wiper motor.
does Distance
not
Vol be 3 1 mm.
-a- to limit stop -2- dshould gu
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Place crank armaut of motor on shaft of wiper motor using se or a
ho e
curing nut -3-.
ss c
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un
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an
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itte
page 178 .
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ility
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1.2.8 Installing the windscreen wiper system
rrectne
Install wiper frame in reverse order of removal. Note when in

stalling that securing pin -2- of wiper frame must be inserted
ss
in grommet -1- in bulkhead.

o
cial p
f inform

mer
page 178 .
atio
om
Fit connector to wiper motor connection and lock in position.

c
i
or
n thi
te
Install air cowling, plenum chamber cover and plenum cham

sd
iva
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ber seal in reverse order of removal.

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t.
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.
Install wiper arms page 160 .
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1.3 Removing and installing wiper arms
Prote AG.
Removing:
Removing wiper arms page 158 .
Installing:
Note
Securing nuts of wiper arms are not tightened to specified torque

until after wiper blade park position has been adjusted.
Deactivate the APP function if not already done page 155 .

To move wiper motors to their park position, switch wind
screen wipers on and off with ignition on.

Place wiper arm in approximate park position on wiper arm

shaft and tighten securing nut -arrows- by hand.
Adjust windscreen wiper blade park position page 161 .
1.4 Adjusting wiper blade park position

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Puller -T10130-
ot
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spec
es, in part or in w
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Note
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On RHD vehicles, the wiper blades are a mirror image.

en
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.
Deactivate the APP function if not already done page 155 .
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Allow wiper to move to park position and then switch ignition
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off.
AG.
Now adjust windscreen wiper blade park position.

Driver's side:
Distance -A- between wiper blade and upper edge of plenum
chamber cover should be 10 mm.
If necessary, adjust wiper blade park position by moving wiper
arm.
Tighten threaded connection to specified torque setting
page 178 . wage
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Front passenger's side:
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Distance -B- between wiper blade and upper edge of plenum
y li
erm
ab
chamber cover should be 10 mm.
ility
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If necessary, adjust wiper blade park position by moving wiper
wit
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arm.
ole,
spec
t to the co
Tighten threaded connection to specified torque setting
page 178 .
rrectness o
cial p
1.5 Removing and installing aerodynamic
f inform
wipers
mer
atio
om
Removing:
n
c
i
or
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te
sd
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Note
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Driver's and front passenger wiper blades should not be inter Cop py
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changed during installation. gh ht
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The aerodynamic wipers are very flexible. To lift the wiper Prote
cted agen
blades off the windscreen, touch them only in the area in which
AG.
the wiper blades are attached to the wipers.

To remove the wiper blades, the wiper arms should be placed
in the service/winter position. Theservice/winter position is
activated within 10 seconds after ignition is switched off by
pressing windscreen wiper lever in tip wipe.
Place wiper arm in service/winter position by operating the

windscreen wiper lever within 10 seconds after ignition is
switched off in tip wipe position.
Lift up wiper arm.

Turn wiper blade -1- on wiper arm onto limit stop -arrow A-.
Pull wiper blade -1- off axis of wiper arm -arrow B-.
Installing:
Slide wiper blade onto axis of wiper arm.
Turn wiper blade on axis of wiper arm onto stop.
Volkswa
Carefully fold wiper arm back down onto
swa
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G. gen AG
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1.6 Removing and installing rain and light
an
itte
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erm
ab
detector sensor -G397-
ility
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Removing:
h re
hole
spec
es, in part or in w
t to the co
Removal wedge -3409-
rrectness of i
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nf
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orm
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atio
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or c
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ignition key.
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Remove interior mirror General body repairs, interior; Rep.
co lksw
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Gr. 68 ; Removing and installing interior mirror . Prote AG.
Pull connector -1- off rain and light detector sensor -G397-
-2-.

Using removal wedge -3409- , lever rain and light detector

sensor -G397- -1- out of retainer -2-.
Note
When removing, ensure to remove the complete rain and light

detector sensor -G397- and not only the upper shell of the sensor.
Installing:
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gen AG does
Installation is performed in the reverse order of installation;
Vol
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when not
doing this, note the following: e d by gu
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Note
ce
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un
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an
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Before installing, thoroughly clean the windscreen, within the
y li
rm
ab
retainer for the rain and light detector sensor -G397- .
pe
ility
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The surface (coupling cushions) of the rain and light detector
wit
, is n
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sensor -G397- must not be soiled when installing.
hole
spec
If the surface (coupling cushions) of the rain and light detector
es, in part or in w
t to the co
sensor -G397- is soiled, it can possibly be cleaned by Apply
ing and Pulling off one or more tapes.
After installing the rain and light detector sensor -G397- there
rrectness of i
must be no air bubbles between windscreen and the surface
(coupling cushions).
l purpos
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mercia
a
com
tion in
r
te o
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olkswagen AG
en AG. V
2 Windscreen washer system
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ss
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ility
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2.1 Assembly overview of windscreen washer system
h re
ole,
spec
t to the co
1 - Y-piece
Distribution of wash wa
ter line to windscreen
rrectne
spray jets
s
2 - Spray jet for windscreen
s o
washer system, right
cial p
f inform
mer
page 169
atio
m
Adjusting page 169

o
n
c
i
or
n thi
e
3 - Spray jet for windscreen

t
sd
va
washer system, left

i
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t.
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page 169
Co
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Adjusting page 169 opy
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4 - Elbow
by
cted agen
Prote AG.
Connection to left wind
screen spray jet
Overview of washer wa
ter line hose couplings
page 174
5 - Hose
Hose repair
page 176
6 - Elbow
Connection to right
windscreen spray jet
page 174
7 - Filler pipe for reservoir for
windscreen washer and head
light washer systems
page 166
8 - Washer pump -V5-
Removing and installing page 168
9 - Windscreen washer system and headlight washer system reservoir
2. Windscreen washer system 165

2.2 Removing and installing reservoir for

windscreen and headlight washer sys
tems
The reservoir for windscreen and headlight washer systems has
three parts. The individual parts are connected together. To en
sure a correct positioning of the individual parts, observe that the
guides of the individual parts run in one another when installing.
1 - Removing and installing filler pipe for windscreen and head
light washer system reservoir page 166
2 - Connecting pipe filler neck/reservoir; the connecting pipe is
removed together with the reservoir for windscreen washer and
headlight washer systems page 167
3 - Removing and installing reservoir for windscreen and head
light washer systems page 167
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2.2.1 Removing and installing filler pipe for ss
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an
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tem reservoir
erm
ab
ility
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Removing:
wit
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hole
Pull filler pipe -1- off union -3- on reservoir for windscreen and
spec
headlight washer systems.
es, in part or in w
Remove securing bolt -2-. t to the co
Unclip hose retainer from filler neck -3- and take it out of the
rrectness of i
vehicle.
l purpos
Installing:
nform
ercia
note the following:

m
at
om
ion
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or
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ate
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The funnel on the underside of the filler pipe should be inserted

p
cum
or
in the hole -arrow-.

f
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Connecting pipe -1- and filler neck -2- must be fitted together so
that the guides -arrows- grip into one another.
2.2.2 Removing and installing reservoir for

tems
Removing:
ignition key.
Remove filler pipe for windscreen and headlight washer sys
tem reservoir page 166 .
Remove front bumper cover Body Repairs, exterior; Rep.
Gr. 63 ; Front bumper . agen AG. Volkswagen AG do
sw es k not
Vol gu
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Note utho eo
ra
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The connections to the pump and hose lines are colour-coded in

nl
pt
du
order to prevent the washer water lines being incorrectly connec

an
itte
y li
ted to the front and rear washer water pump -V5- . The hose
erm
ab
fittings must be inserted into the correct colour-coded pump con

ility
ot p
nections during assembly.

wit
, is n
h re
hole
spec
To unlock, turn the securing clips hose connections -3- and

es, in part or in w
-5- and pull them out of the windscreen washer pump -V5-
t to the co
-4-.
If necessary, collect washer fluid that leaks out with a suitable
rrectness of i
container.
l purpos
Separate the connector -6- of windscreen washer fluid level

sender -7-.
nf
ercia
Take washer pump -V5- -4- upwards out of reservoir and sep
or
arate connector -2-.

m
m
atio
m
Pull headlight washer system pump -V11- -9- upwards out of

o
n in
or c
reservoir and separate connector and separate connector

thi
te
-10-.
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Cop py
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Prote AG.

Unbolt securing bolts -arrows- and take reservoir out of vehi

cle.
Installing:
note the following:
page 178 .
Bleed the headlight washer system after completing work
page 173 .
AG. Volkswagen AG d
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itte
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erm
ab
2.3 Removing and installing washer pump -
ility
ot p
wit
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V5-
h re
hole
spec
Removing:
es, in part or in w
t to the co
ignition key.
rrectness of i
Gr. 63 ; Front bumper .
l purpos
Note
nform
mercia
at
The connections to the pump and hose lines are colour-coded in
om
ion
order to prevent the washer water lines being incorrectly connec
c
in t
or
ted to the front and rear windscreen and rear window washer
his
ate
pump -V59- . The hose fittings must be inserted into the correct
do
priv
c
colour-coded pump connections during assembly.
um
for
en
ng
t.
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op
To unlock, turn the securing clips hose connections -3- and C py
ht. rig
-5- and pull them out of the windscreen washer pump -V5- rig ht
py by
-4-.
co Vo
by lksw
cted agen
Prote AG.
If necessary, collect fluid leaking out with a suitable container.
Pull washer pump -V5- -4- upwards out of the reservoir.
Installing:
note the following:
page 178 .
page 173 .

2.4 Removing and installing windscreen

washer spray jets
Removing:
Push spray jets upwards -arrow A- and pull 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.
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gen AG d
Push spray jet inoinstallation
lksw
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hole until it isoheard
es n
ot g to lock in
place. byV ua
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Adjust aspray
ut
h jets page 169 . ra
ss c
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pe
ility
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wit
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2.5 Adjusting front windscreen washer sys

h re
hole
spec
tem spray jets

es, in part or in w
t to the co
Note
rrectness of i
If the spray field is not uniform because the spray jet is soiled,
l purpos
remove the spray jet and clean in opposite direction of spray with
water. In the following it is allowed to blow the spray jets in op
posite direction of spray with compressed air. Do not use objects
nform
ercia
to clean the spray jets.

m
a
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tion in

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Cop py
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rig ht
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co Vo
by lksw
cted agen
Prote AG.

3 Headlight washer system
Note
Current flow diagrams, Electrical fault finding and Fitting loca

tions
Every fifth time the front 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 - provided
either dipped beam or high beam are switched on.
The active time of the headlight washer system can be variably
adjusted to between 0 and 12.75 seconds page 294 .
To guarantee sound functioning, the headlight washer system
must be vented following assembly work or when activated for the
first time page 173 .
The onboard supply control unit -J519- is equipped with self-di
AG. Volkswagen AG d
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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Prote AG.

3.1 Assembly overview - headlight washer system

AG. Volkswagen AG d
agen oes
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1 - Washer ised spray
b jet assembly ara
nte
with right
ut
hor
spray jets eo
a ra
s Removing and installing
s c
spray jet assembly
ce
e
nl
pt
du
page 173
an
itte
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Adjusting spray jets
erm
ab
ility
page 173
ot p
wit
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pop-up spray jet cylin
hole
spec
der page 172
es, in part or in w
t to the co
2 - Washer spray jet assembly
with left spray jets
rrectness of i
spray jet assembly
l purpos
page 173
Adjusting spray jets
page 173
nform
ercia

m
at
pop-up spray jet cylin
om
ion
der page 172
c
in t
or
his
te
3 - Elbow
a
do
priv
Connection to left spray

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for
en
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jet pop-up cylinder

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t.
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C py
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gh
ht
pyri by
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page 174
o
by c lksw
cted agen
Prote AG.
4 - Hose
5 - Elbow
Connection to right
spray jet pop-up cylin
der
Distribution of washer
water to spray jets on
headlight washer sys
tem
Overview of washer water line hose couplings page 174
6 - T-piece
Distribution of washer water to spray jets on headlight washer system
7 - Elbow
8 - Headlight washer system pump -V11-
9 - Windscreen washer system and headlight washer system reservoir
10 - Filler pipe for reservoir for windscreen washer and headlight washer systems
3.2 Removing and installing headlight

washer system pump -V11-
The headlight washer system pump -V11- is fitted on the wind
screen and headlight washer system in the right housing liner.
3. Headlight washer system 171

Removing:
ignition key.
Pull headlight washer system pump -V11- -9- upwards out of
the reservoir.
To remove the connecting pipe -8- pull securing clip on con
nection and pull connecting pipe -8- off headlight washer
system pump -V11- .
Installing:
note the following:
page 178 .
page 173 .
AG. Volkswagen AG d
agen oes
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3.3 Removing and installing pop-up spray d byV
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Removing: s
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un
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ignition key.
rm
ab
pe
ility
Pull spray jets with cap -1- out of bumper cover onto stop.
ot
wit
, is n
h re
Unclip cap -1- from mounting points -arrows- on washer spray
hole
jet assembly.
spec
es, in part or in w
t to the co
Pull the securing clip -4- off hose connection. rrectness of i

l purpos
Pull hose connection off pop-up cylinder -2-.

nform
ercia
Unclip pop-up spray jet cylinder -2- from bracket -3-.

m
a
com
tio
Installing:
n in
r
te o
thi

s
iva
do
note the following:

r
rp
cum
fo
The pop-up spray jet cylinder hose must be attached to the

en
ng
t.
yi
securing clip on the bracket.
Co
Cop py
ht. rig
ht
rig by
opy Vo
page 178 . by c lksw
cted agen
Prote AG.
page 173 .

AG. Volkswagen AG d
agen oes
olksw not
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rise nte
autho
Jetta e2005
or , Bora 2006
ac
ss Electrical System - Edition 05.2005
ce
e
nl
pt
du
an
3.4 Removing and installing spray jet as
itte
y li
erm
ab
sembly
ility
ot p
wit
, is n
Removing:
h re
hole
spec
es, in part or in w
ignition key.
t to the co
Pull spray jet with cover cap -1- onto stop out of bumper cover.
Unclip cap -1- from mounting points -arrows- on washer spray
rrectness of i
jet assembly.
l purpos
nform
ercia
Lever locking hooks -arrow- up slightly and pull out spray jet
m
assembly.
at
om
ion
c
Installing:
in t
or
his
ate
do
priv
cum
or
Note
f
en
ng
t.
yi Co
op py
The degree to which the cover cap of the spray jet is pulled down t. C rig
gh ht
onto the bumper cover can be adjusted using the clips on the yri
p by
o Vo
washer spray jet assembly. If the washer spray jet assembly is
c by lksw
cted agen
not pulled in far enough, the cover cap will not seat correctly. If
Prote AG.
the washer spray jet assembly is pulled in too far, the cover cap
and the bumper cover could be pushed out of shape.
Push washer spray jet assembly in pop-up cylinder until it en

gages.
Fit cover cap on washer spray jet assembly and allow pop-up
cylinder to retract.
Check the cover cap is seated correctly on the bumper cover.
If necessary, adjust seat of cover cap by pushing washer spray
jet assembly in higher or lower position on pop-up cylinder.
page 173 .
Check headlight washer system spray jets and adjust if nec
essary page 173 .
3.5 Adjusting headlight washer system jets

3.6 Bleeding the headlight washer system

To guarantee sound functioning, the headlight washer system
must be bled following assembly work or when operated for the
first time.
Fill reservoir for windscreen and headlight washer systems.
Start the engine.
Switch ON the headlight.
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.
3. Headlight washer system 173

4 Wash water line hose couplings

The following hose coupling types are used to connect the hoses
to pumps and spray jets and/or as points of separation:
. Volkswagen AG
gen AG
4.1 Windscreen and reary Vwindow washer
wa does
olks not
gu
system d b ara
ise nte
or h eo
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Pull the two coupling sections
ss apart (no
a
securing device) to c
loosen the connection.
ce
le
un
pt
an
d
To secure the connection, push the two coupling sections to

itte
y li
rm
gether, until you hear and feel them engage.
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
To loosen the connection, rotate the lock ring -1- by 90

-arrow- and pull off the hose connection.
nform
ercia
To secure the connection, push on the hose connection and

m
a
rotate the lock ring -1- -arrow- until it engages.
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
To loosen the connection, pull up the lock ring -1- by approx.

1 mm -arrow- and pull off the hose connection.
To secure the connection, push on the hose connection and
push in the lock ring -1- until it engages.

4.2 Headlight washer system

To loosen the connection -1- push the lock ring -arrow- and
pull off the hose connection.
To secure the connection, push and hold the lock ring
-arrow- and push on the hose connection. Check that the se
curing clip has correctly engaged by depressing and trying to
pull off without the clip.
lkswage es n
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byV ua
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u or
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itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
4. Wash water line hose couplings 175

5 Hose repair
A new repair concept has been developed for repair work on wash
system hoses. Various connectors, special EPDM hoses (ethyl
ene propylene diene monomer) and heat-shrink hose are availa
ble as spare parts
5.1 General description

The replacement parts can be found in the parts catalogue
(ETKA).
Replacement parts are available for repair of both smooth and
corrugated pipes.
5.2 Repairing smooth pipe

Smooth pipe with a diameter or 5x1 mm or 6x1 mm can be re
paired with EPDM hose. . Volkswage n AG n AG d
wage oe
Cut damaged section Vol at right angles out of smooth
ks s no
t pipe
gu which
is to be repaired.d by ara
ise n r tee
ho
Select thes auappropriate
t
EPDM hose -2- and cable ties accord
or
ac
ing to the parts catalogue (ETKA).
s ce
le
un
pt
Cut EPDM hose -2- so that ends -1- and -3- of smooth pipe
an
d
itte
y li
can each be pushed about 10 mm into the EPDM hose -2-.

erm
ab
ility
ot p
wit
is n
h re
Secure the repair joints with cable ties -1-.

ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
5.3 Repairing corrugated pipe

iva
o
pr
cum
r
fo

en
ng
t.
yi Co
op py
Hot air gun -VAS 5179- or t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Hot air gun -V.A.G 1416/- or

Hot air blower -VAS 1978/14-

lkswage Jetta 2005
es n , Bora 2006
o ot
byV Electrical System g-uaEdition 05.2005
d ran
ir se tee
tho o
au ra
c
ss
ce
Note
e
nl
pt
du
an
itte
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Repair points must not be subjected to pulling or bending
erm
ab
forces.
ility
ot p
wit
, is n
If the damaged section is longer than 20 mm, a new piece of
h re
corrugated pipe must be used and the procedure described
hole
spec
below must be performed twice.
es, in part or in w
t to the co
Cut damaged section at right angles out of corrugated pipe
which is to be repaired.
rrectness of i
Select the appropriate connectors -2- and -3- as well as the
l purpos
appropriate heat-shrink hose according to the parts catalogue

(ETKA).
nform
ercia
Heat end of corrugated pipe -1-.

m
at
Push connector -2- into corrugated pipe -2- -arrow A-.
om
ion
c
in t
Heat end of corrugated pipe -4-.
or
his
ate
do
riv
Push connector -3- into corrugated pipe -4- -arrow B-.

p
cum
for
en
ng
t.
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op
Cut heat-shrink hose so that ends of corrugated pipe are each
C py
t. rig
gh
covered by about 20 mm -dimension x- of heat-shrink hose.
ht
pyri by
Vo
co lksw
by
cted
Push heat-shrink hose over corrugated pipe, join connectors
agen
Prote AG.
and secure repair joints with heat-shrink hose.
5. Hose repair 177

6 Torque settings: Windscreen wash/wipe system

Wiper motor to wiper frame M6 8 Nm
Motor crank arm to wiper motor shaft M8 18 Nm
Wiper frame to body M6 8 Nm
Windscreen wiper arms to wiper motor M8 20 Nm
shaft
Windscreen washer system and headlight M6 8 Nm
washer system reservoir
Pop-up spray jet cylinder front bumper 4.5 Nm
cover
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

94 Lights, lamps, switches - outside

1 Headlight
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 is first under
stood.
In the vehicle there are fitted headlights of three different manu
facturers:
AL (Automotive Lighting)
Hella
Removal and installation of the headlights and its attachments is
the same, only the removing and installing of the actuator motors
are different.
The onboard supply control unit has a self-diagnosis function,
which makes fault finding on the headlights easier.
AG. Volkswagen gen AG do
swa es n
For fault finding, use the vehicle diagnosis,
by
Vol testing and informa
k ot g
ua
tion system -VAS 5051A- in guided ris
e fault finding mode.
d ran
tee
ho
ut or
1.1 Assembly overview,
ss
a
Headlight ac
ce
e
nl
pt
du
an
itte
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Note
erm
ab
ility
ot p
In the overview there are shown the three control motors of the
wit
, is n
different headlight manufacturers because their removal and in

h re
hole
stallation is different.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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t.
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co lksw
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Prote AG.
1. Headlight 179
1 - Securing bolts lkswage es n
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byV ua
4 Nm ir se
d ran
tee
tho
or
2 - Adjustment bushes
ss
au ac
Correcting installation
ce
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pt
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position of headlight
an
itte
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page 182
erm
ab
ility
ot p
3 - Left headlight main beam
wit
bulb -M30- or right headlight
, is n
h re
main beam bulb -M32-
hole
spec
Bulb H7U 12 V, 55 W
es, in part or in w
t to the co
Renewing page 185
4 - Left side light bulb -M1- or
right side light bulb -M3-
rrectness of i
Bulb 12 V, W 5 W
l purpos
Renewing page 187
nform
ercia
5 - Cover cap
m
6 - Front left turn signal bulb -
at
om
io
M5- or front right turn signal
n
c
in t
r
bulb -M7-
o
his
ate
Bulb 12 V, PY 21 W
do
priv
cum
or
Renewing page 188

f
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7 - Bulb holder with grip ele . Cop py
ment
t rig
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For front left turn signal
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bulb -M5- or front right Prote AG.
turn signal bulb -M7-
8 - Body section
9 - Cover cap
10 - Bulb holder with grip ele
ment
For left headlight dipped
beam bulb -M29- or right headlight dipped beam bulb -M31-
11 - Left headlight dipped beam bulb -M29- or right headlight dipped beam bulb -M31-
Bulb H7 12 V, 55 W
Renewing page 184
12 - Headlights
Correcting installation position of headlight page 182
Servicing headlight securing lugs page 188
180 Rep. Gr.94 - Lights, lamps, switches - outside

1.2 Removing and installing headlights
1.2.1 Removing headlights
Note
It is not necessary to disconnect the battery earth strap.

The diagrams show how the left headlight is removed and in
stalled.
If a headlight is removed, it should always be adjusted Main
tenance ; Booklet 20.1 .
If a headlight with gas discharge lamps is removed, a basic
setting must be performed to adjust the headlights Mainte
nance ; Booklet 20.1 .
ignition key.
Release multi-pin connector -arrow- and pull off multi-pin con
nector.
Remove front bumper General body repairs; Rep. Gr. 63 ;
Front bumper
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Unscrew securing screw -arrow- on upper headlight.

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
Unscrew securing screw -arrow- on lower left headlight.

his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Headlight 181
Unscrew securing screw -arrow- on lower right headlight.
1.2.2 Installing headlights

Tighten all securing bolts to specified
wage
n AG. Volktorque setting
swagen AG do
es n
page 238 . y Volks ot g
b ua
ed ra
Check headlighthorinstallation
is position is central, i.e. shutlines
nte
eo
are equal around
sa
ut
headlight. ra
c s
If the shutlines around the headlight are uneven, the installation
ce
e
nl
pt
du
position must be adjusted page 182 .

an
itte
y li
erm
ab
Check function of headlight.
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
If a headlight is removed, it should always be adjusted.

t to the co
Check headlight setting and adjust headlight as necessary

rrectness of i

l purpos
1.3 Adjusting headlight installation position

nform
ercia
Note
m
at
om
ion
c
To adjust the headlight installation position, the front bumper

in t
or
his
e
must not be removed.

at
do
priv
The diagrams show the left headlight.

um
for
en
ng
t.
yi Co
op
If it transpires during checking of the installation position that the
C py
t. rig
gh
shutlines between headlight and body are uneven, the installation
ht
pyri by
Vo
position must be adjusted.
co lksw
by
cted agen
Prote AG.
ignition key.
Remove radiator General Body Repairs, Exterior; Rep. Gr.
66 ; Strips and trim .

agen
AG. Volkswagen AG d
oes
olksw not
V g
by ua
Unscrew securing screwris
ed -arrow- on upper headlight. ran
tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Unscrew securing screw -arrow- on lower left headlight.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
Unscrew securing screw -arrow- on lower right headlight. cted agen
Prote AG.
Adjust shutlines to body by pushing in or pulling out alignment

bush -arrow- on lower left or lower right headlight.
page 238 .
Check and, if necessary, readjust headlight to ensure gaps are
even all round.
Install radiator General Body Repairs, Exterior; Rep. Gr.
66 ; Strips and trim; Removing and installing radiator .
Note
If a headlight is removed or adapted to the body it should always

be adjusted after installing or adapting it.

1. Headlight 183
1.4 Renewing headlight bulbs
1.4.1 Renewing dipped beam headlight bulb
Note
The diagrams show renewal of the dipped beam headlight bulb swa
gen AG
. Volkswagen AG
does
for the left headlight. by
Volk not
gu
ara
ed nte
ris
ho e
Removing: au
t or
ac
ss
ce
le
un
pt
ignition key.
an
d
itte
y li
rm
Turn cover cap -1- in -direction of arrow- and remove.
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
Turn bulb holder with dipped beam headlight bulb -1- in
com
tio
-direction of arrow- and remove from headlight.
n in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Pull dipped beam headlight bulb -2- in -direction of arrow- out

of bulb holder -1-.
Installing:
Note
When installing cap, ensure that it is seated correctly. The in

gress of water will lead to permanent damage of the headlight.
Do not touch bulb glass when fitting bulbs. Fingers leave
traces of grease on the glass, which evaporate when the bulb
is switched on and cause the glass to cloud over.

Place headlight dipped beam bulb -1- in the bulb holder that
the pin on the dipped beam headlight bulb lies in the recess
-arrow- of bulb holder -2-.
Place bulb holder with dipped beam headlight bulb -1- in head
light and turn bulb holder with dipped beam headlight bulb in
-direction of arrow-.
Place cover cap -1- in headlight recess and

AG. Vtighten
olkswagein
n AG d
agen
-direction of arrow-. Vo lksw
oes
not
y gu
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or
ise nte
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Check headlight setting
ss
a and adjust headlight as necessary c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.4.2 Renewing main beam headlight bulb

rrectness of i
l purpos
Note
The diagrams show renewal of the main beam headlight bulb for
nform
ercia
the left headlight.

m
at
om
ion
Removing:
c
in t
or
his
te
a
do
riv
ignition key.
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Headlight 185
Pull off cover cap -1-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Pull off multi-pin connector -2-.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
Press spring retaining clip -2- in -direction of arrow- under the
o
m
f
en
ng
locking lugs-1- and fold spring retaining clip -2- upwards.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Take headlight main beam bulb -1- out of the headlight.

Installing:
Note



Place the headlight main beam bulb -1- in the recesses

-arrows- on the headlight.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
1.4.3 Renewing side light bulb
ed
ris nte
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aut ra
ss c
ce
le
un
Note
pt
an
d
itte
y li
rm
ab
The diagrams show renewal of the side light bulb for the left
pe
ility
headlight.
ot
wit
, is n
h re
hole
Removing:
spec
es, in part or in w
t to the co
ignition key.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
Pull, depending on the cable length, the bulb holder -1- with
py by
co Vo
by lksw
the side light bulb as far it is possible out of the reflector.
Prote
cted AG.
agen
1. Headlight 187
Pull side light bulb -2- in -direction of arrow- out of the bulb
holder -1-.
Installing:
Note


Maintenance ; Booklet 20.1 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se
1.4.4 Renewing front turn signal bulb utho tee
or
a ac
ss
ce
le
un
pt
Note
an
d
itte
y li
erm
ab
The diagrams show renewal of the turn signal bulb for the left
ility
ot p
headlight.
wit
is n
h re
ole,
spec
Removing:
t to the co
ignition key.
Turn bulb holder with front turn signal bulb -1- in direction of
rrectne
arrow and remove from headlight.
s
Push front turn signal bulb into bulb holder, turn front turn sig
s o
nal bulb anti-clockwise and pull front turn signal bulb out of
cial p
f in
bulb holder.
form
mer
Installing:
atio
om
n
c
i
or
n thi
te
Note
sd
iva
o
pr
cum
r
fo
When installing bulb holder, ensure that the seal is seated

en
ng
t.
yi Co
correctly. The ingress of water will lead to permanent damage Cop py
of the headlight.
t. rig
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pyri by
Vo
o
c by lksw
cted agen
Prote AG.

1.5 Servicing headlight securing lugs

Information on servicing headlight securing lugs was not available
when it was time of going to press.

1.6 Adjusting headlights

Adjusting headlights Maintenance ; Booklet 20.1 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
1. Headlight 189
2 Main headlights with gas discharge

bulbs
Note
Before working on gas discharge headlights, always switch off

the headlights and remove the ignition. key.
Volkswag AG en AG
agen do
The automatic headlight range
yV
olks control on headlights with
w es n
otgas
g
discharge bulbs is equipped
ise
db with self-diagnosis. ua
ran
or tee
When dealing with utcomplaints, it is absolutely essential that
h
a
or
ac
the function andssoperation of the lighting system is first under
ce
e
stood.
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
tions
es, in part or in w
t to the co
The automatic headlight range adjustment (HRA) and onboard
rrectness of i
supply control unit have a self-diagnosis function, which makes
fault finding on the headlights using gas discharge lamps easier.
l purpos
tion system -VAS 5051A- in guided fault finding mode. nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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o
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cu
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m
f
en
ng
t.
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Cop py
t. rig
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Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
ksw
agen oes
not
Vol
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2.1 tho Assembly overview - gas discharge headlights
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After any measures which could affect the headlight setting, the headlight must be checked and if necessary
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adjusted Maintenance ; Booklet 20.1 .
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1 - Vent hose
t to the co
On headlight
2 - Left headlight range control
rrectne
motor -V48- or right headlight
range control motor -V49-
ss
Headlight manufactur
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Lighting)
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3 - Securing bolts
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For left headlight range

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control motor -V48- or
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4 - Cover cap Prote AG.
5 - Gas discharge light starter

unit -N195-
6 - Bulb locking
For left gas discharge
bulb -L13- or right gas
discharge bulb -L14-
7 - Left gas discharge bulb -
L13- or right gas discharge
bulb -L14-
Type D2S, 35W
Renewing page 192
8 - Securing bolt
4 Nm
On upper headlight
9 - Headlights
Servicing headlight securing lugs page 204
10 - Headlight range control unit -J431-
Coding page 200
Note
11 - Front left vehicle level sender -G78-

Checking page 203 .
2. Main headlights with gas discharge bulbs 191

12 - Rear left vehicle level sender -G76-

Checking page 203 .
13 - Adjustment bush
14 - Securing bolt
4 Nm
On lower headlight
15 - Left gas discharge light control unit -J343- or right gas discharge light control unit -J344-
Not capable of self-diagnosis
16 - Securing bolts
For left gas discharge light control unit -J343- or right gas discharge light control unit -J344-
17 - Left headlight main beam bulb -M30- or right headlight main beam bulb -M32-
Bulb H7U 12 V, 55 W
Renewing page 194
18 - Front left turn signal bulb -M5- or front right turn signal bulbAG. -M7-
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Renewing page 197 ris
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19 - Left side light bulb -M1- or right side light
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a bulb -M3- ra
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Bulb 12 V, W 5 W
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Renewing page 196
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20 - Cover cap
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For front left turn signal bulb -M5- or front left turn signal bulb -M7- and for left side light bulb -M1- or right
, is n
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side light bulb -M3-
hole
spec
21 - Cover cap
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t to the co
For left headlight main beam bulb -M30- or right headlight main beam bulb -M32-
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2.2 Removing and installing headlights
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Removing and installing headlights page 181 .

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2.3 Adjusting headlight installation position

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Adjusting headlight installation position page 182 .

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2.4 Renewing headlight bulbs

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2.4.1 Renewing gas discharge bulb Cop py
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Note
Prote AG.
The diagrams show renewal of a gas discharge bulb for the left
headlight.
Removing:
Remove headlight page 181 .

Turn cover cap -1- in -direction of arrow- and remove.
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Pull off connector -1-.
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Note
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The connector is ejected automatically when the gas discharge
bulb starter unit -N195- is removed.
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Turn gas discharge bulb starter unit -N195- -1- in direction of

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starter unit lettering OPEN and pull gas discharge bulb start
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er unit -N195- off headlight.
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WARNING yri
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Within the bulb glass of gas discharge bulbs, pressures
AG.
can range from between 7 bar (cold) and 100 bar (hot).
Temperatures can reach up to 700 degrees Celsius on the
glass bulb.
The glass bulb may explode resulting in a risk of injury
from burning.
Always wear eye protection and gloves when removing
and installing gas discharge bulbs!
Turn bulb retainer -1- in -direction of arrow- and remove bulb

retainer.

Carefully pull gas discharge bulb -1- out of mounting.

Installing:
Note
Do not touch bulb glass when fitting a gas discharge lamp

bulb . Fingers leave traces of grease on the glass, which when
switching the gas discharge lamp bulb on, evaporate and
cause the glass to cloud over.
Use extreme care when fitting a gas discharge lamp bulb and
do not subject the bulb to mechanical stress. The glass bulb
is extremely sensitive and is subjected to a very high pressure.
Avoid looking directly into the collimated beam as the UV rays
from the gas discharge bulb are about 2.5 times greater than
normal halogen bulbs.
If a headlight is removed with automatic range control, the ba
sic setting of the headlight should always be checked when
reinstalling Maintenance ; Booklet 20.1 .

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2.4.2 Renewing main beam headlight bulb ol not
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The following diagrams show renewal of the main beam headlight

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bulb for the left headlight.

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Removing:
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ignition key.
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Pull connector off -arrow-.
Press spring retaining clip -2- in -direction of arrow- under the

locking lugs-1- and fold spring retaining clip -2- upwards.
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Take main beam bulb -1- out of headlight.
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Installing:
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Note
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is switched on and cause the glass to cloud over. nform
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Place the headlight main beam bulb -1- in the recesses

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-arrows- on the headlight.

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2.4.3 Renewing side light bulb
Note
The following diagrams show renewal of the side light bulb for the
left headlight. AG. Volkswagen A n G do
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Switch off ignition and all electrical consumers
au
th and pull out or
ac
ignition key. ss
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Pull, depending on the cable length, the bulb holder -2- with
the side light bulb as far it is possible out of the reflector -1-.
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Pull side light bulb -2- in -direction of arrow- out of the bulb
holder -1-.
Installing:
Note



2.4.4 Renewing front turn signal bulb
Note
The following diagrams show renewal of the turn signal bulb for
the left headlight.
Removing:
ignition key.
Pull, depending on the cable length, the bulb holder -1- with n AG. Volkswagen AG do
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the front turn signal bulb in -direction of arrow- and take them olks es n
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out of the reflector. se
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Push front turn signal bulb -2- into bulb holder -1- and turn front
turn signal bulb -2- in -direction of arrow-.
rrectness of i
Pull front turn signal bulb -2- out of the bulb holder -1-.
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Installing:
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is switched on and cause the glass to cloud over. Cop py
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2.5 Removing and installing headlight range

control motor
Information was not available when it was time of going to press.
2.6 Removing and installing gas discharge

light control unit AG. Volkswagen n AG do
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The left gas discharge light control unit -J343- or the right gas
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discharge light control unit -J344- are not capable of self-diagno

un
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Removing:
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Remove headlight page 181 .
ole,
spec
Remove securing bolts -arrows- of gas discharge light control
t to the co
unit -1-.
rrectne
Note
When taking off the gas discharge light control unit the connectors
ss o
must not be removed. The connector is fitted tightly to the head
cial p
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light and is automatically disconnected when taking off the gas
form
mer
discharge light control unit .
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Take off gas discharge light control unit -1- from headlight. i
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Installing:
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When installing the gas discharge light control unit secure correct
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seat of the seal. The ingress of water will lead to permanent dam
agen
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age of the headlight.

Perform basic setting of headlights Maintenance ; Booklet
20.1 .
2.7 Headlight range control unit -J431-
2.7.1 Removing and installing headlight range

control motor -J431-

Removal wedge -VAS 3409-
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When removing and installing components in visual area (con
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nectors, covers, trims etc.) apply a commercial adhesive tape
h re
hole
where a lever tool is applied ( removal wedge -VAS 3409- , srew
spec
driver).
es, in part or in w
t to the co
Removing:
rrectness of i
ignition key.
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Remove lateral cover -1- out of the dash panel, by inserting

the removal wedge -VAS 3409- or a screwdriver in the recess
nform
ercia
-2- and lever off cover-1- in -direction of arrow-.

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Unlock the locking clip -1- in -direction of arrow- and pull off
connector -2- from control unit for headlight range control -
J431- .

Unscrew securing bolt -arrow- and take control unit for head
light range control -J431- -1- of bracket -2-.
Installing:
Fit the control unit for headlight range control -J431- -3- into
the bracket -2- with the lug -2-.
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Lock connector au-1- by pressing the locking clip -2- in
t or
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-direction of arrow-. ss
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After installing a new control unit for headlight range control -

, is n
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J431- , it must be coded page 200 .

hole
spec
es, in part or in w
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rrectness of i
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2.7.2 Coding control unit for headlight range

control -J431-
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Automatic headlight range control utho eo
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Automatic headlight range control functions s
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Coding automatic headlight range control
an
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Note
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spec
If the control unit for headlight range control -J431- has been co
es, in part or in w
ded, the basic setting of the headlights must be performed after
t to the co
having coded the control unit Maintenance ; Booklet 20.1 .
2.8 Vehicle level sender
rrectness of i
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There is a vehicle level sender located on the front axle ( front left
vehicle level sender -G78- ) and on the rear axle ( rear left vehicle
level sender -G76- ).
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Note
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If the vehicle level senders are replaced, check the values from
iva
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the sensors page 203 and carry out basic setting on head
rp
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lights Maintenance ; Booklet 20.1 .
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If the values from the vehicle level sensors are outside the
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specified tolerance, basic headlight setting cannot be carried
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2.8.1 Removing and installing front left vehicle

level sender -G78-
Removing:
ignition key.
Pull off connector -arrow-.

Remove securing nut -1-.

Unscrew securing bolt -2- and remove front left vehicle level
sender -G78- -3-.
Installing:
note the following:
page 238 .
Check front left vehicle level sender -G78- page 203 .
Perform basic setting of headlights Maintenance ; Booklet
20.1 .
Note
If the vehicle level sensors are replaced, check the sensor

values page 203 and carry out basic setting on headlights
Maintenance ; Booklet 20.1 .
out.
2.8.2 Removing and installing rear left vehicle

level sender -G76-
Removing:
Switch off ignition and all electrical
agen consumers and
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Pull off connectorth-arrow-.
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Unscrew the five securing bolts -1- and remove rear left vehi
cle sender -G76- -2-.
Installing:
note the following:
Tighten threaded connections to specified torque settingsAG. Volkswagen AG d
page 238 . agen oes
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Check front left vehicle level sender -G76-
or
ise page 203 . nte
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Perform basic setting of headlights
ss Maintenance ; Booklet
a c
20.1 .
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Note
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If the vehicle level sensors are replaced, check the sensor
h re
hole
values page 203 and carry out basic setting on headlights
spec
Maintenance ; Booklet 20.1 .
es, in part or in w
t to the co
out.
rrectness of i
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2.8.3 Checking vehicle level sender
nf
ercia
The vehicle level senders transmit the longitudinal inclination an
orm
gle of the vehicle by way of signals to the headlight range control
m
atio
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unit -J431- .
o
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It must then be confirmed whether the rear left vehicle level sen
te
sd
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sor -G76- and front left vehicle level sensor -G78- are supplying
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the headlight range adjustment unit -J431- with plausible signals.
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No fault entry is stored in the headlight range control unit -J431-
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Vehicle level senders installed are not of type specified in this
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Vehicle level senders have mechanical fault

Vehicle suspension has been modified (e.g. lowered)
Note
If the values of the vehicle level senders are outside the specified
tolerance, basic headlight setting cannot be carried out.

Body
Electrical System
Automatic headlight range control
Automatic headlight range control functions
Checking vehicle level sender

2.9 Servicing headlight securing lugs

Information on servicing headlight securing lugs was not available
when it was time of going to press.
2.10 Adjusting headlights

Adjusting headlights with gas discharge lamp Maintenance ;
Booklet 20.1 .
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3 Fog lights
The onboard supply control unit has a self-diagnosis function,
which makes fault finding on the fog lights easier.
3.1 Assembly overview - fog light

Torque settings page 238
1 - Front bumper wage

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2 - Vent hose byV ua
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3 - Left fog light bulb -L22- or auth or
ac
right fog light bulb -L23- ss
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Bulb H11 12 V, 55 W
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page 206
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4 - Fog light housing
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page 205
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5 - Cover cap
6 - Securing bolts
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7 - Spreader nuts
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3.2 Removing and installing fog lights
Note
The diagrams show how the left fog light is removed and installed.
3. Fog lights 205

Removing:
ignition key.
Remove bolt -2-.
Unclip cover cap -2- off locking device.
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Pull fog light housing out of front bumper and disconnect con
ility
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nector -arrow-.
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Installing:
hole
spec
es, in part or in w
t to the co
Check functions of headlight.
rrectness of i
Check fog light adjustment, adjusting if necessary Mainte
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nform
mercia
at
3.3 Removing and installing fog light bulb

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The diagram shows how the left fog light is removed and installed.
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Removing:
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Remove fog light page 205 .

Turn bulb holder -1- in -direction of arrow- and take out of fog
light.
The bulb for the fog light is permanently attached to the bulb
holder and cannot be renewed separately.
Fog light bulb : H11 12 V, 55 W
Installing:
Check functions of headlight.
Check fog light adjustment, adjusting if necessary Mainte
3.4 Adjusting fog lights

Adjusting fog lights Maintenance ; Booklet 20.1 .
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3. Fog lights 207

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4 Removing and installing side marker
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in front bumper
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4.1 Removing and installing front side mark
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er
Removing
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Note
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Removal and installation of front side marker on left and right are
mer
identical.
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Rep. Gr. 50 ; Assembly overview - noise insulation
sd
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Unlock side marker -1- by pressing the locking lug

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-in direction of arrow-.

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Remove bulb holder -2- out of side marker.
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Installing
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Note
After the installation perform functional check.
4.1.1 Renewing side marker bulb

Pull side marker bulb -1- in direction of arrow out of the bulb
holder -2-.

5 Mirror turn signal bulb and entry light

in exterior mirror
Note

tions
The exterior mirror turn signal bulbs are located in the housing of
the exterior mirror.
Furthermore there is located an entry light on each side in the
housing, which illuminates the entry area around the driver and
front passenger side.
1 - Driver side exterior mirror turn signal bulb -L131- or front pas
senger side exterior mirror turn signal bulb -L132-
2 - Driver side entry light in exterior mirror -W52- or front passen
ger side entry light in exterior mirror -W53-
The onboard supply control unit is equipped with self-diagnosis AG. Volkswagen AG d
which makes fault finding easier. lksw
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For fault finding, use the vehicle diagnosis, testing andriinforma
se
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tion system -VAS 5051A- in guided fault finding mode.utho or
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5.1 Removing and installing turn signal bulb

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The driver side exterior mirror turn signal bulb -L131- or the front
erm
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passenger side exterior mirror turn signal bulb -L132- is installed
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in the housing of the left or right exterior mirror.
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Note
t to the co
The complete driver side exterior mirror turn signal bulb -L131- or
the complete front passenger side exterior mirror turn signal bulb
rrectness of i
-L132- must be replaced if damaged.
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Removing:
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ignition key.
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Remove driver side exterior mirror turn signal bulb -L131- or

n
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the front passenger side exterior mirror turn signal bulb -L132-
his
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General Body Repairs, Exterior; Rep. Gr. 66 ; Exterior rear

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Installing:
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Install driver side exterior mirror turn signal bulb -L131- or the cop Vo
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front passenger side exterior mirror turn signal bulb -L132-
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General Body Repairs, Exterior; Rep. Gr. 66 ; Exterior rear
view mirror; Removing and installing side mounted turn sig
nals .
5. Mirror turn signal bulb and entry light in exterior mirror 209
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5.2 Removing and installing entry light in ex r nte
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The driver side entry light in exterior mirror -W52- or the front
an
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passenger side entry light in exterior mirror -W53- is installed in
erm
ab
the housing of the left or right exterior mirror.
ility
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hole
Note
spec
es, in part or in w
t to the co
To remove and install the entry lights the exterior mirror must
not be removed.
Removal and reinstallation of entry lights is carried out in the
rrectness of i
same manner on both sides and is described for one side only.
l purpos
Removing:
nform
ercia
m
ignition key.
at
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Fold exterior mirror -1- in -direction of arrow- forwards.
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Unbolt securing bolt -1-.
Unclip entry light in -direction of arrow- out of the exterior mirror

and pull it out as far as possible.

Pull bulb carrier -2- in -direction of arrow- out of entry light

housing -1-.
Renew bulb:
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Pull bulb -1- in -direction of arrow- out of the carrier -2-.
rm
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Plug base bulb: 12 V, W6 W
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Installing:
h re
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spec
es, in part or in w
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Note
rrectness of i
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After the installation perform functional check of the exterior mir

ror.
nform
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a
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tion in
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5. Mirror turn signal bulb and entry light in exterior mirror 211
6 Tail lights
6.1 Assembly overview - tail light in side panel

1 - Securing nuts
2 - Left brake and tail light bulb
-M21- or right brake and tail
light bulb -M22-
3 - Tail light housing in side
panel
page 212
4 - Bulb for left brake, blinker
and tail light 2 -M72- or bulb for
right brake, blinker and tail light
2 -M73-
5 - Bulb carrier
page 213
AG. Volkswagen AG d
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spec
t to the co
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6.2 Removing and installing tail light in side

s
panel
s o
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f in
Removing:
form
mer
atio
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ignition key.
n
c
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Press side trim to side.

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Pull connector -1- off.

Remove securing nuts -2- on tail light in side panel.
Remove tail light.
Installing:
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un
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Tighten securing nuts -2- to specified tightening torque
an
d
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page 238 .
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Note
h re
ole,
spec
The tail light connector in the side panel must audibly engage.
t to the co
When installation is complete, check shutlines of tail light to
body.
rrectness o
cial p
f in
6.3 Removing and installing tail light bulb
form
mer
carrier in side panel
atio
om
n
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Removing:
thi
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Unclip retaining tabs -1- -in direction of arrow- and take bulb
carrier out of tail light housing -2-.
Installing:
6. Tail lights 213

6.4 Assembly overview - tail light in tailgate

1 - Securing nuts
2 - Bulb carrier
page 215
3 - Left reversing light bulb -
M16- or right reversing light
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4 - Tail light housing in tailgate aut
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Removing and installing s
ce
le
page 214
un
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an
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itte
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5 - Plain washer
erm
ab
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spec
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6.5 Removing and installing tail light in tail

gate
Removing:
ignition key.
Unclip service cover out of trim in tailgate

AG. Volkswagen AG d
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autho
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ra
ss Electrical System - Edition 05.2005
c
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Remove securing nuts -1- on tail light in tailgate.
ility
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Remove tail light.
h re
hole
Installing:
spec
es, in part or in w
t to the co
rrectness of i
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nform
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Secure washer -2- with an adhesive point (e.g. Loctite) before

m
fitting on threaded domes -1-, to prevent from falling in the
at
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io
body.
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Fit the washers -2- on the threaded domes -1-.

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Tighten securing nuts -1- to specified tightening torque

page 238 .
Fit connector -2- on bulb carrier.
When installation is complete, check shutlines of tail light to
body.
6.6 Removing and installing tail light bulb

carrier in tailgate
Removing:
ignition key.
Unclip service cover out of trim in tailgate
Note
The lower tail light trim must not be removed. For reasons of
clarity the lower tailgate trim is not shown in the following figure.
6. Tail lights 215

Unclip the two retaining tabs -in direction of arrow- and take
bulb carrier -1- out.
Installing:
AG. Volkswagen AG d
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7 Number plate lights
7.1 Removing and installing number plate

light -X-
Removing:
ignition key.
Remove securing bolts -arrows- of number plate light -X- .
Take the lens off together with the number plate light -X- .
Number plate light -X- : Soffitte 12 V, C 5 W
Installing:
AG. Volkswagen AG d
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7. Number plate lights 217

8 Additional brake light
8.1 Removing and installing high level brake

light bulb -M25-
Note
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In the event of damage, the complete high level brake light -M25- Vol
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unit must be renewed. ise
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Removing: ss
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ignition key.
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Remove strip roof leading edge General body repairs, in
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terior; Rep. Gr. 70 ; Removing and installing strip roof leading
, is n
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edge .
hole
spec
es, in part or in w
t to the co
Press high level brake light bulb -M25- to rear window
-in direction of arrow-
rrectness of i
Installing:
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9 Steering column switch
Caution

AG. Volkswagen AG d
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After installing a new tsteering
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-J527- , it must be coded
s au page 227 . ra
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In the event of faults in the steering column switch, the coding
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of the steering column electronics control unit -J527- must be
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checked page 227 .
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The steering column electronics control unit -J527- is equipped
spec
with self-diagnosis, which is designed to ease fault finding.
t to the co
rrectness o
cial p
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mer
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9. Steering column switch 219

9.1 Assembly overview - steering column switch
1 - Turn signal switch

page 224
The turn signal switch lkswage es n
comprises of the follow d byV
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ing components turn o
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ran
tee
signal switch -E2- , auth or
ac
headlight dipper/flasher ss
switch -E4- and, if fitted
ce
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un
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with cruise control sys
an
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itte
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tem cruise control sys
erm
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tem switch -E45-
ility
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the turn signal switch
ole,
without cruise control
spec
system switch -E45-
t to the co
2 - Steering column switch
base
rrectne
page 226
ss
3 - Windscreen wiper switch -
o
cial p
f
E-
inform
mer
atio
page 225
om
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4 - Securing bolt
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5 - Steering column electronics

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control unit -J527- cum

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Final control diagnosis Prote AG.
page 227
6 - Airbag coil connector and
return ring with slip ring -F138-
7 - Steering angle sender -G85-
Basic settings page 228
9.2 Removing and installing steering col

umn switch
Caution


Note
When removing the steering column switch, observe that no metal

shavings/swarf enter the steering column switch when drilling out
the shear head bolts.
Removing:
For removal of the complete steering column switch, inc. base
module, the switch is dismantled and the steering lock housing is
also removed. For assembly of the steering lock housing, new
shear head bolts are required. Even if just one component of the
steering column switch is removed or renewed, the sequence de
scribed as follows must be observed.
G. Volkswage
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Rep. Gr. 68 ; Compartments, covers by
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Remove components of steering
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a column switch in the sequence ra
c
as follows:
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un
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an
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Steering column electronics control unit -J527- page 221

itte
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Airbag coil connector and return ring with slip ring -F138-
ility
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page 223
wit
is n
h re
Steering angle sender -G85- page 224
ole,
spec
Turn signal switch page 224
t to the co
Windscreen wiper switch -E- page 225
Steering column switch base page 226
rrectne
Installing:
ss

o
cial p
f inform
9.2.1 Removing and installing steering col

mer
atio
umn electronics control unit -J527-

om
n
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Note
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t.
After new control unit has been installed, it must be coded
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9.3 Steering column electronics control unit J527 ,
C py
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page 227 .
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In the event of faults in the steering column switch, the coding
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of the control unit must be checked page 227 .

AG. Volkswagen AG d
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Jetta 2005 , Bora 2006ise d b ara
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Electrical System - Edition
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s
Removing:
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Unscrew bolt -1-.
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Insert a thin rod, e.g. of 2.5 mm -2- approx. 45 mm in the
ot
wit
hole -arrow 1- in steering column electronics control unit -
, is n
h re
J527- to release the locking tab -arrow 2-.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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tion in
r
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thi
s
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Using a screwdriver, press against the rear securing clip
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t.
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-arrow- of the steering column electronics control unit -J527- .
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Carefully pull the steering column electronics control unit - yri
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Unclip -arrow A- connector -1- and separate from steering col

umn electronics control unit -J527- .
Remove locking device -3- out of connector.
Unclip -arrow B- connector -2- and separate from steering col
umn electronics control unit -J527- .
Installing:
Note
Ensure when fitting the connector that none of the pins become
bent and that the connector can be heard to engage.

9.2.2 Removing and installing coil connector

for airbag and reset ring with slip ring -
F138-
Removing:
Note
The coil connector should not be moved out of the central position
during removal and the road wheels should be in the straight
ahead position.
Lift up locking tabs -arrows- on coil connector -1- slightly and

pull coil connector backwards off steering column and steering
column switch.
Installing:
Note
For installation of the coil connector,

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in the central positionolandagen
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The central
ss position
(depending on manufacturer) of
a the coilr acon
c
nector is shown in the following diagram:
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mer
The coloured strip (black rectangles) -arrow- must be in view

atio
m
-1-.
o
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c
i
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The coloured strip (yellow) -arrow- must be in view -1-.

thi
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If a new steering angle sensor -G85- is installed, this procedure
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must be followed by a basic setting page 228 .
co Vo
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9.2.3 Removing and installing steering angle

sensor -G85-
Removing:
Pull the steering angle sender -G85- -1- backwards and away
from the steering column switch -arrow-.
Installing:
9.2.4 Removing and installing turn signal

switch swage
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Note utho
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The turn signal switch comprises of the following compo
e
nl
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nents turn signal switch -E2- , headlight dipper/flasher switch
an
itte
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-E4- and, if fitted with cruise control system cruise control sys
erm
ab
tem switch -E45-
ility
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, is n
For reasons of clarity, the steering column switch is shown with
h re
cruise control system switch -E45- .
hole
spec
es, in part or in w
t to the co
Removing:
Release retaining clips -arrows- using a 1.0 mm feeler gauge
-1- and take turn signal switch off backwards.
rrectness of i
Installing:
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Note
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The turn signal switch should be heard to engage.

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9.2.5 Removing and installing windscreen orised by ara
nte
wiper switch -E- h eo
aut ra
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Removing:
nl
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Note
ility
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For reasons of clarity, the steering column switch is shown in the
hole
spec
removed state.
es, in part or in w
t to the co
Release retaining clips -arrows- using 1.0 mm feeler gauge
-1- and take windscreen wiper switch -E- off backwards.
rrectness of i
Installing:
l purpos

nf
ercia
orm
m
Note
atio
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n in
or c
The windscreen wiper switch -E- should be heard to engage.
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9.2.6 Removing and installing base module of

steering column switch
Note
To remove the base module of the steering column switch -2- -,

the shear head 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 basic brace

agen
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have been removed before boring the shearVohead
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an
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Caution
spec
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Removing:
ss
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Remove the following components in sequence:
mer
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Remove steering column trim General body repairs, interior;

sd
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Rep. Gr. 68 ; Compartments, covers and trim; Removing and

pr
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installing steering column switch trim .

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Remove steering column electronics control unit -J527- C py
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page 221 .
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Remove coil spring for airbag/coil connector with slip ring - cted agen
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F138- page 223 .
Remove steering angle sender -G85- page 224 .
Remove the turn signal light switch -E2- page 224 .
Remove windscreen wiper switch -E- page 225 .
Disconnect connector -arrow- at reader coil -3-.
The basic brace can be removed once all the components moun
ted on it have been dismantled:
Drill out securing bolts -1- of steering lock housing -3-.
Note
Bolts M8 -1-, core diameter 6.8 mm.

Pull steering lock housing and base module of steering column

switch -2- to rear off steering column.
Take steering lock housing off base module of steering column
switch.
Installing:
Place the steering lock housing into the basic for the steering
column switch.
Push base module of steering column switch -2- as far as
possible onto steering column.
Fit connector -arrow- at reader coil -3-.
Tighten the new shear head bolts -1- to steering column.
Tighten the new shear head bolts -1- until bolt heads shear off.
Install all parts in reverse order of removal.
9.3 Steering column electronics control unit

-J527-
Removing and installing steering column electronics control unit
-J527- page 221
9.3.1 Coding steering column electronics con

trol unit -J527- G. Volkswage nA n AG d
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in Vehicle Diagnosis, Testing and or
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Steering wheel electronics

Steering wheel electronics functions
rrectness of i
Coding control unit for steering wheel electronics

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9.3.2 Steering column electronics control unit

-J527- final control diagnosis
nform
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Steering wheel electronics
Steering wheel electronics functions

Steering wheel electronics final control diagnosis
9.4 Steering angle sender -G85-

Removing and installing steering angle sender -G85-
page 224
9.4.1 Basic setting steering angle sender -

G85-
Running gear
Brake system
01 - Mark 60/Mark 70 systems, capable of self-diagnosis
Anti-lock braking system ABS/EDL/TCS/ESP Mark 60
Function
Basic setting steering angle sensor (00778-3132) -G85-
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n AG. Volkswagen AG do Jetta 2005 , Bora 2006
wage es n
yV
olks ot g Electrical System - Edition 05.2005
d b ua
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10 Ignition switch and lock cylinder
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10.1 Removing and installing steering lock
ab
pe
ility
housing
ot
wit
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
rrectness of i
l purpos
Note
nform
mercia
To remove steering lock housing it is necessary to remove the
a
com
tio
steering column switch base first.
n in
r
te o
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iva
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Caution
um
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The steering lock could be destroyed.
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If the steering lock is actuated without lock cylinder, it will
p by
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lksw
block and must be renewed.
by
cted agen
Prote AG.
The steering lock must not be actuated without lock cylin

der.
Removing:
Remove basic brace for steering column switch page 226
10.2 Removing and installing lock cylinder
Caution
Disconnecting and connecting the battery as described in

the Workshop Manual page 29 .
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:
Remove steering column trim General body repairs, interior;
installing steering column switch trim .
Remove steering column electronics control unit -J527-
page 221 .
10. Ignition switch and lock cylinder 229

Remove coil spring for airbag/coil connector with slip ring -

F138- page 223 .
Remove steering angle sender -G85- page 224 .
Note
For reasons of clarity, the diagram is shown without turn signal

and windscreen wiper switch. There is no need to remove the
switches for removal of the lock cylinder.
The immobilizer reader coil is secured to the lock cylinder and
cannot be replaced individually.
Disconnect connector -arrow- at reader coil.
Insert ignition key in lock cylinder and turn to position Drive.

Position of key in lock cylinder:
1 - Position Stop
2 - Position Drive
3 - Position Start
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Note
is n
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spec
For reasons of clarity, the diagram shows a removed lock cylinder
without ignition key. t to the co
Insert steel rod (approx. 1.2 mm) in drilling -arrow- adjacent

to ignition key.
rrectne
Using steel rod -2- disengage -arrow- safety bar -3- of lock
s
cylinder -1-.
s o
cial p
f i
Pull lock cylinder -1- out of steering lock housing.

nform
mer
atio
om
n
c
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Installing:
Note
For reasons of clarity, the ignition key is not shown in the following
diagram.
Insert ignition key in lock cylinder -1- and turn to position

Drive.
Using steel rod -2- disengage -arrow- safety bar -3- of lock
cylinder -1-.
Place lock cylinder -1- in steering lock housing.
Note
The connection for the immobilizer reader coil must be inserted

in the steering lock housing guide.
Pull steel rod -2- out of lock cylinder -1- and check lock cylinder
is seated correctly in the steering lock housing.
Fit connector to immobilizer reader coil.
10.3 Removing and installing ignition switch

AG. Volkswagen AG d
agen oes
olksw not
V
Caution d by gu
ara
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Disconnecting and connecting the battery
ss au
as described in the ra
c
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un
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Removing: ab
ility
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Pull connector -2- off ignition switch -1-.

spec
Release ignition switch using small screwdriver -arrows-.

t to the co
Pull ignition switch -1- out of steering lock housing.

rrectne
Installing:
Insert ignition switch in steering lock housing until it can be
ss
heard to engage.
o
cial p
f inform
mer
atio
om
n
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or
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Prote AG.
10. Ignition switch and lock cylinder 231

Note
Position of key in lock cylinder:

1 - Position Stop
2 - Position Drive
3 - Position Start
10.3.1 Removing and installing ignition key

withdrawal lock solenoid -N334-
The ignition key withdrawal lock solenoid -N334- is located di
rectly adjacent to the ignition starter key.
Note AG. Volkswagen AG d

agen oes
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To remove ignition key on vehicles withisean d b automatic gearbox,
y ara
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always move selector lever to position thor P first then switch off ig eo
nition. Otherwise the ignition key withdrawal
s au
lock solenoid -N334- ra
c
will inhibit the removal of the ignition key.
s
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Removing:
erm
ab
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Remove steering column electronics control unit -J527-

wit
page 221 .
, is n
h re
hole
Release locking device -2- using a screwdriver.

spec
es, in part or in w
Pull ignition key withdrawal lock solenoid -N334- -1- in direc

t to the co
tion of arrow and out of its mounting.

The electrical connection will be disconnected automatically.
rrectness of i
Installing:
l purpos
Installation is performed in the reverse order of installation;

when doing this, note the following:
nform
mercia
at
om
io
Note
n
c
in t
or
his
te
After reconnecting the battery, carry out final control diagnosis to

a
do
riv
activate ignition key withdrawal lock solenoid -N334-

p
cum
or
page 227 .
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11 Parking aid
Note
. Volkswagen AG
gen AG
For complaints with the parkingksaid
wa system it is absolutely
oes es d
not
Vol
sential to understand theefunction
db
y and operation of the system.guara
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or
Additional information
au Operating instructions
th eo
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The parking aid system or PDC (Park Distance Control) supports
erm
ab
the driver during parking maneuvers by indicating the distance
ility
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from the rear of the vehicle to the obstacle by way of acoustic
wit
, is n
signals.
h re
hole
spec
The parking aid system comprises:
es, in part or in w
t to the co
Parking aid control unit -J446-
Rear parking aid warning buzzer -H15-
rrectness of i
Rear left centre parking aid sensor -G204-
l purpos
Rear left inner parking aid sensor -G334-

Rear right inner parking aid sensor -G335-
nf
ercia
orm
Rear centre right parking aid sender -G205-
m
atio
om
n in
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thi
te
The parking aid system is equipped with self-diagnosis, which is

sd
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designed to simplify fault finding.

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tion system -VAS 5051A- in guided fault finding mode. C py
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To check the entire parking aid system, perform final control di cop Vo
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agnosis page 236 . cted agen
Prote AG.
11. Parking aid 233

11.1 Assembly overview - parking aid
1 - Parking aid system warning

buzzer -H15-
Below the rear shelf
page 236
2 - Parking aid control unit -
J446-
Behind right luggage
compartment trim panel
page 234
3 - Rear centre right parking
aid sender -G205-
In the rear bumper cover
page 235
4 - Rear right inner parking aid
sensor -G335-
page 235
5 - Rear left inner parking aid gen AG. Volkswagen AG
does
sensor -G334- olks
wa not
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In the rear bumper rised cover
b ara
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o eo
Removing aand ut
h
installing ra
page 235 ss c
ce
e
nl
pt
6 - Rear centre left parking aid

du
an
itte
sender -G204-
y li
erm
ab

ility
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, is n
h re
page 235
hole
spec
es, in part or in w
t to the co
11.2 Removing and installing parking aid

rrectness of i
control unit -J446-

l purpos
The parking aid control unit is located behind the right luggage
compartment panel trim.
nf
ercia
Removing:
rm
m
atio
m
o
n in
c
ignition key.
or
thi
te
sd
a
Remove right side panel trim in luggage compartment Gen

iv
o
r
rp
cu
eral body repairs, interior; Rep. Gr. 70 ; Load and luggage

o
m
f
en
area trims .
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t.
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Prote AG.

Remove connectors -1- by pressing the locking tabs

-arrows- inwards.
Press locking tabs -arrows- of the retainer outwards and take

parking aid control unit -1- out of the retainer.
Installing:
11.3 Removing and installing parking aid

sensor G. Volkswagen nA AG do
wage es n
Following 4 senders are located iny Vthe
olks rear bumper cover. ot g
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b
ed ran
Rear centre left parking thaid
or sender -G204-
is tee
or
au ac
Rear left inner parking
ss aid sensor -G334-
ce
e
nl
pt
Rear right inner parking aid sensor -G335-

du
an
itte
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erm
Rear centre right parking aid sender -G205-

ab
ility
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Note
hole
spec
es, in part or in w
Removal and installation of the rear parking aid sensor is carried

t to the co
out in the same way for all sensors and is described below for just
one sensor.
rrectness of i
Removing:
l purpos
ignition key.
nform
ercia
Remove rear bumper cover General body repairs, exterior;

m
at
Rep. Gr. 63 ; Rear bumper .

om
ion
c
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or
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ate
do
priv
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for
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Prote AG.
11. Parking aid 235

Release locking lugs -arrows- and pull sender out of bumper

cover.
Installing:
. Volkswagen AG
gen AG
11.4 Removing and installing rear parking ksw aid
a does
not
y Vol gu
b
warning buzzer -H15-
ara
ed nte
ris
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ut ra
The rear parking aid warning buzzer -H15- is ss fitted on the
a
rear c
shelf plate. It is accessible via the luggage compartment.
ce
e
nl
pt
du
an
Removing:
itte
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erm
ab
Pull off connector -1-.
ility
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wit
, is n
Release securing clips -arows- remove rear parking aid warn

h re
hole
ing buzzer -H15- from retainer.

spec
es, in part or in w
Installing:
t to the co

rrectness of i
l purpos
nf
ercia
orm
m
atio
m
11.5 Final control diagnosis

o
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Using the Go to key, select Function/component selection cop Vo
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and the following menu items one after the other: cted agen
Prote AG.
Body
General Body Repairs
Parking aid

Parking aid functions

Final control diagnosis
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spec
es, in part or in w
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rrectness of i
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nf
ercia
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Prote AG.
11. Parking aid 237

12 Torque settings: lights, bulbs,

switches - exterior
12.1 Torque settings: headlight

Upper headlight 4 Nm
Lower left headlight 4 Nm
Lower right headlight 4 Nm
12.2 Torque settings: fog lights

Headlight securing screws 1,5 Nm
12.3 Torque settings - tail light in side panel

Securing nuts 3.5 Nm 0.5 Nm
12.4 Torque settings - tail light in tailgate

Securing nuts 3.5 Nm 0.5 Nm
12.5 Torque settings: vehicle level sender lksw

agen
AG. Volkswagen AG d
oes
not
o
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Threaded connections rised Torque settings nte
ho eo
Front left vehicle level sender -G78- M6 aut 9 Nm ra
ss c
Rear left vehicle level sender -G76- M5 5 Nm
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
r
te o
thi
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iva
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238
by lksw
cted agen
Rep. Gr.94 - Lights, lamps, switches - outside Prote AG.
96 Lights, lamps, switches - inside

1 Lights and switches in engine com
partment
Note
The Jetta or the Bora have no lights in the engine compartment.

wage es n
1.1 Removing and installing bonnet contact olks ot g
byV ua
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switch -F266- tho
ir se tee
or
au ac
ss
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le
un
pt
Note
an
d
itte
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erm
ab
The bonnet contact switch -F266- is integrated into the bonnet
ility
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lock and cannot be replaced individually.
wit
is n
h re
If the bonnet contact switch -F266- is found to be defective,
ole,
spec
the entire bonnet lock must always be replaced.
t to the co
Remove front bonnet lock General Body Repairs, Exterior;
Rep. Gr. 55 ; Bonnet; Removing and installing coupling lock;
Removing .
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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Prote AG.
1. Lights and switches in engine compartment 239

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-
Light switch illumination bulb -L9-
Removing:
wage es n
Switch off the ignition and all electrical consumers. y Vo lks ot g
ua
b
ed ran
Turn grip of light switch to position 0. horis tee
ut or
a ac
Push in grip of light switch -1- and turn it to sthe
s right slightly
-2-.
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e
nl
pt
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an
itte
Hold rotary part in this position and pull lighting switch (using
y li
erm
ab
rotary part) out of dash panel -3-.
ility
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
or
m
m
atio
om
Installing:
n in
or c
thi
e
Fit connector to light switch.

t
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Prote AG.
Hold light switch and press rotary position indicator of light

switch firmly inwards -1- and turn slightly to right -2-.
Hold grip in this position and insert light switch in dash panel
-3-.
Turn rotary knob to 0 release and engage switch.
240 Rep. Gr.96 - Lights, lamps, switches - inside

2.2 Removing and installing glove compart

ment light -W6-
Note
When removing and installing components in visual area (con gen AG

. Volkswagen AG
does
nectors, covers, trims etc.) apply a commercial adhesive ol swa
ktape not
V gu
where a lever tool is applied ( removal wedge -VAS ised3409-
by
, srew ara
nte
driver). thor eo
au ra
c
ss
Removing:
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nl
pt
du
an
itte
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erm
ab
Lever lens carefully out using removal wedge -VAS 3409- or
ility
ot p
a screwdriver.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m

o
n in
or c
thi
e
Renew bulb:
t
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iva
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cted agen
Prote AG.
2. Lights and switches in dash panel 241

Unlock locking tabs -1- and take thermal protection plate -2-
off the lens or the light.
Lever bulb carefully out of the holder. AG. Volkswagen AG d

agen oes
olksw not
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Renew glas base bulb (12 V, 5 W). ed b ara
nte
ris
ho eo
Installing: aut ra
c
ss
ce
le
un
pt
note the following:
an
d
itte
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rm
ab
Check functions of glove box switch. The lamp must not light
pe
ility
when the lid is closed.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2.3 Removing and installing glove compart
ment light switch -E26-
rrectness of i
l purpos
The glove compartment light switch can be found on the rear of

the glove compartment.
nform
ercia
Removing:
m
a
com
tion in
r
Remove glove compartment General body repairs, interior;

te o
Rep. Gr. 68 ; Compartments, covers and trim; Removing and thi

s
iva
do
installing glove compartment .
r
rp
cum
fo
en
g
Unlock locking lug -1- and slide the switch out of the guide
n
t.
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op
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Installing: copy Vo
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cted agen
Prote
AG.
2.4 Removing and installing switches and

instruments illumination regulator -E20-
Removing:
Remove light switch page 240 .
Remove stowage compartment on driver side General body
repairs, interior; Rep. Gr. 68 ; Compartments, covers and trim .

lkswage es n
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ss
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pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
Unlock locking lugs -arrows- and take adjuster and regulator
hole
out.
spec
es, in part or in w
t to the co
Installing:
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e
2.5 Removing and installing front passenger

t
sd
iva
o
r
rp
side airbag deactivated warning lamp - cu

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m
f
en
ng
K145-
t.
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Cop py
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Removing:
ht
pyri by
Vo
co lksw
by
cted
agen
Prote AG.
Remove centre vent Heating, air conditioning system; Rep.

Gr. 80 ; Servicing heating system; remove vent; Remove cen
tre vent .

Unlock locking lugs -arrows- and take warning lamp out.

Installing:
2.6 Removing and installing hazard warning

light switch -E3- olkswagen AG. V
olkswagen AG
does
no t gu
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Removing: db ara
rise nte
tho eo
Switch off the ignition and
s au all electrical consumers. ra
c
s
ce
e
Remove centre vent Heating, air conditioning system; Rep.

nl
pt
du
Gr. 80 ; Servicing heating system; remove vent; Remove cen
an
itte
y li
tre vent .
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
Release locking lugs -arrows- and remove hazard warning

or
thi
light switch.
te
sd
iva
o
r
Installing:
rp
cu
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m
f
en
ng
t.
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cted agen
Prote AG.
2.7 Removing and installing left footwell

light -W9- and right footwell light -W10-

lkswage es n
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ir se tee
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ss
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le
un
pt
Note
an
d
itte
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erm
ab
ility
ot p
wit
is n
where a lever tool is applied ( removal wedge -VAS 3409- ,
h re
ole,
srewdriver).
spec
The removal and installation of both footwell lights is the same
t to the co
so that only one light is described.
rrectne
Removing:
ss o
Lever footwell light out of the trim under the dash panel using
cial p
f in
removal wedge -VAS 3409- or a screwdriver.
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
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by
cted agen
Prote AG.

Renew bulb:

Unlock locking tabs -1- and take thermal protection plate -2-
off the lens or the light.
Lever bulb carefully out of the holder.

Renew glas base bulb (12 V, 5 W).
Installing:
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
2.8 Removing and installing key operated

nl
pt
du
an
itte
switch to deactivate front passenger
y li
erm
ab
side airbag -E224-
ility
ot p
wit
, is n
h re
hole
WARNING
spec
es, in part or in w
t to the co
Observe safety measures when working on airbag General
body repairs, interior; Rep. Gr. 69 ; Safety measures when
working on airbags .
rrectness of i
l purpos
Removing:
nf
ercia

orm
m

atio
m

o
n in
or c

thi
te
sd
iva

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r
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f
en
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Prote AG.

Release locking lugs -arrows- and remove key switch.

Installing: n AG. Volkswagen AG do
lkswage es n
Install in reverse order of removal. d byV
o ot g
ua
ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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3 Lights and switches in front doors th
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3.1 Removing and installing window regula
erm
ab
ility
tor switch in front passenger door -
ot p
wit
is n
E107-
h re
ole,
spec
t to the co
Note
The window regulator switch in front passenger door -E107- fea
rrectne
tures a button illumination bulb -L76- , which must not be replaced
individually.
ss o
cial p
f
Removing:
inform
mer
atio
om
Remove lever shell, upper part out of the closing lever Gen
n
c
i
or
n
eral body repairs, interior; Rep. Gr. 70 ; Removing and instal
thi
te
sd
a
ling door trim; Front door trim, front passenger side .

iv
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fo
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Release locking lugs -arrows- and remove switch from the in

stallation frame.
Installing:
3.2 Removing and installing switch module

for driver side mirror adjustment
The following components (depending on equipment) are inte
grated into the switch module for the driver side mirror adjustment:
Mirror adjustment switch -E43-
Mirror adjustment reversing switch -E48-
Exterior mirror heater button -E231-
Mirror fold-in feature system switch -E263-
Mirror adjustment switch illumination bulb -L78-

Note
In the event of repair, the complete component must be renewed.
Removing:
Remove switch module window lifter, driver side
page 250 .
Unclip installation frame for switch from trim.
stallation frame.
Installing:
Install in reverse order of removal. AG. Volkswagen AG d
agen oes
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or eo
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un
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rm
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3.3 Removing and installing driver side in
h re
hole
terior locking button for central locking
spec
es, in part or in w
system -E308-
t to the co
rrectness of i
Note
l purpos
The driver side interior locking button for central locking system -
E308- features a button illumination bulb -L76- , which must not
nform
ercia
be replaced individually.
m
a
com
ti
Removing:
on in
r
te o
thi

s
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do
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rp
Remove door trim General body repairs, interior; Rep. Gr.

cum
fo
70 ; Removing and installing front door trim, driver side .

en
ng
t.
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op
Disconnect connector -1- and tighten securing bolts -2-.
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Take door opener with switch out of the door trim.
op Vo
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Prote AG.
3. Lights and switches in front doors 249

Release locking lugs -arrows- and remove interior locking

switch from the installation frame.
Installing:
AG. Volkswagen AG d
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d by ara
3.4 Components - front door locks ise nte
or eo
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aut ra
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The following components (depending on equipment) are inte s
ce
e
grated into the driver side door lock:

nl
pt
du
an
itte
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Driver door contact switch -F2-
erm
ab
ility
ot p
Driver side central locking lock unit -F220-
wit
, is n
h re
Driver door central locking motor -V56-
hole
spec
Driver door central locking deadlock function motor -V161-
es, in part or in w
t to the co
grated into the passenger side door lock:
rrectness of i
Front passenger door contact switch -F3-
l purpos
Front passenger side central locking lock unit -F221-

Front passenger seat central locking motor -V57-
nform
ercia
Front passenger door central locking deadlock function motor

m
at
-V162-
om
ion
c
in t
or
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ate
Note
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In the event of component defects - front door locks: yri
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cted
Replace relevant door lock General Body Repairs, Exterior;
agen
Prote AG.
Rep. Gr. 57 ; Front door; Removing and installing door lock .
3.5 Removing and installing switch module

for driver side window lift

AG. Volkswagen AG d
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Note by Vo gu
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th
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nectors, covers, trims etc.) apply
s a commercial adhesive tape
s c
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nl
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driver).
an
itte
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ab
ility
ot p
The following components (in models with 4 doors) are integrated
wit
into the switch module for the driver side window lift:
, is n
h re
hole
Front left window regulator switch -E40-
spec
es, in part or in w
Rear left window regulator switch, in driver door -E53-
t to the co
Rear right window regulator switch, in driver door -E55-
rrectness of i
Front right window regulator switch in driver door -E81-
l purpos
Childproof lock button -E318-

Button illumination bulb -L76-
nform
mercia
at
om
Note
ion
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or
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at
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for
The following components (in models with 2 doors) are integrated
en
ng
t.
yi
into the switch module for the driver side window lift:
Co
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Front left window regulator switch -E40-
ht
pyri by
Vo
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by
cted
Front right window regulator switch in driver door -E81-
agen
Prote AG.
Button illumination bulb -L76-
Note
Removing:
Carefully lever installation frame out of door trim using removal
wedge -VAS 3409- or screwdriver -arrow-.


stallation frame.
Installing:
AG. Volkswagen AG d
agen oes
olksw not
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3.6 Removing and installing remote release

erm
ab
ility
button for fuel filler flap and rear lid -

ot p
wit
is n
E463- and key operated switch to block

h re
ole,
release of rear lid remote -E232-

spec
t to the co
Note
rrectne
The remote release button for fuel filler flap and rear lid -E463-
features a button illumination bulb -L76- , which must not be
ss
replaced individually.
o
cial p
f inform
mer
Removing:
atio
m

o
n
c
i
or
n thi
e
Remove door trim General body repairs, interior; Rep. Gr.

t
sd
va
70 ; Door trim; Removing and installing front door trim, driver

i
o
pr
cum
r
side .
fo
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ng
t.
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Disconnect connector -arrow-. ht. Cop py
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rig ht
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cted agen
Prote AG.

Release locking lugs -arrows- and remove switch from the

door trim.
Installing:
AG. Volkswagen AG d
agen oes
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y V gu
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rise nte
tho eo
au ra
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nl
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du
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ab
ility
ot p
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
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for
en
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Prote AG.

4 Lights and switches in rear doors
4.1 Components - front door locks

grated into the rear left door lock:
Rear left door contact switch -F10-
Rear left central locking lock unit -F222- . Volkswagen AG
gen AG does
swa
Rear left door central locking motor, lock -V214- y Volk not
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Rear left door central locking deadlock function motor horis
-V163- eo
aut ra
The following components (depending on equipment) s are inte
s c
ce
grated into the rear right door lock: le
un
pt
an
d
itte
Rear right door contact switch -F11-
y li
erm
ab
ility
Rear right central locking lock unit -F223-
ot p
wit
is n
Rear right door central locking motor, lock -V215-
h re
ole,
spec
Rear right door central deadlock function locking motor -V164-
t to the co
Note
rrectne
ss o
In the event of component defects - rear door locks:
cial p
f inform
Replace relevant door lock General Body Repairs, Exterior;
mer
Rep. Gr. 58 ; Rear door; Removing and installing door lock .
atio
om
n
c
i
4.2 Removing and installing rear left window
or
n thi
te
sd
a
regulator switch, in door -E52- and rear

iv
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pr
cum
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right window regulator switch, in door -

fo
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ng
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E54-
Co
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Removing: op Vo
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cted agen
Prote
AG.
Remove lever shell, upper part out of the closing lever Gen
ling door trim; Rear door trim .

AG. Volkswagen AG d
agen oes
olksw not
d by
V
Jetta 2005 gu, Bora 2006
ara
e nte
horis Electrical System - Edition e o05.2005
aut ra
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un
stallation frame.
pt
an
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itte
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Installing:
erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
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n
c
i
or
n thi
te
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4. Lights and switches in rear doors 255

5 Lights and switches in luggage com

partment
5.1 Removing and installing luggage com

partment light -W3-
Special tools and workshop equipment
gen AG
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kswagen AG
d wa oes
olks not
Removal wedge -VAS
d b 3409-
yV gu
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utho eo
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t to the co
rrectness of i
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Note
The luggage compartment light can be found on the right side

nform
ercia
in the luggage compartment trim.

m
at
om

ion
c

in t
or

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ate
srewdriver).
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for
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Removing:
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Switch off the ignition and all electrical consumers. gh ht
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by
Lever light out of the luggage compartment trim using removal Prote
cted AG.
agen
wedge -VAS 3409- or a screwdriver.


Renew bulb:
Press contact plate -1- of the light outwards and take festoon
bulb -2- out of the socket.
Renew festoon bulb (12 V, 10 W).
Installing:
5.2 Removing and installing rear lid lock unit

-F256- ksw
agen
AG. Volkswagen AG d
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n
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The rear lid lock unit -F256-
ise
db is integrated into the tailgate lock
ua
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an
cannot be replacedthoindividually.
r tee
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sa c
If the rear lid lock
s unit -F256- is found to be defective, the entire
ce
e
tailgate lock must always be replaced.

nl
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Renew tailgate lock General Body Repairs, Exterior; Rep.

erm
ab
Gr. 55 ; Tailgate; Removing and installing coupling lock; Re

ility
ot p
moving .
wit
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spec
es, in part or in w
t to the co
rrectness of i
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nf
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or c
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5. Lights and switches in luggage compartment 257

6 Lights and switches in roof trim
6.1 Removing and installing front interior

light and reading light (vehicles with no
sliding sunroof)
The following components are integrated in the interior light and
reading light:
Front interior light -W1-
Left centre reading light -W39-
Note
The interior light and reading light as well as the switches for the
interior light and reading light are connected together and can not
be separated. When repairing, renew the complete component.
6.1.1 Removing and installing front interior

light and reading light
Removal wedge -VAS 3409- n AG. Volkswagen AG do
lkswage es n
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byV ua
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ir se tee
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u or
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ility
ot p
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spec
es, in part or in w
t to the co
rrectness of i
Note
l purpos

nf
ercia

orm
driver).
m
atio
om
n in
or c
Removing:
thi
te
sd
iva

o
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rp
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o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Carefully lever trim out of interior light using removal wedge -

VAS 3409- or screwdriver -arrow-.
AG. Volkswagen AG d
agen oes
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ab
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ility
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wit
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spec
Take the interior light out of the headliner console.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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Installing:
en
ng
t.
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op
Install in reverse order of removal. C py
ht. rig
rig ht
py by
co Vo
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cted agen
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6.1.2 Replace front interior light -W1-

6. Lights and switches in roof trim 259

Note

driver).
Removing:
wage
e ks s no
Vol t gu
Carefully lever lens for interior lightedout
by using removal wedge ara
-VAS 3409- or screwdriver -arrow-.
thoris nte
eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Press contact -1- of light to side -arrow- and remove festoon
bulb -2- with the contact from the interior light.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
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cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
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Pull contact -arrow- off defective festoon bulb.
c by lksw
cted agen
Prote AG.
Fit the contact to the new festoon bulb (12 V, 10 W).
Installing:
6.1.3 Left centre reading light -W39- and right

centre reading light -W40-
Removing:
Remove interior light page 258 .

Turn bulb holder -arrows- of the defective reading light for 90

to the left.
Take the holder with the bulb out of the reading light.
Pull glas base bulb carefully out of the holder.

Renew glas base bulben(12
AG.V,
Vol5
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wagen AG
ag does
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Installing: y Vol gu
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Install in reverse
tho order of removal. eo
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ility
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spec
6.2 Removing and installing front interior

es, in part or in w
t to the co
light and reading light (vehicles with slid

ing sunroof)
rrectness of i
The following components are integrated in the interior light and

l purpos
reading light:
Front interior light -W1-
nform
ercia

m
a
com
tion in

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thi
Sunroof switch -E8-

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t.
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Note
Co
Cop py
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interior light and reading light are connected together and can not
Prote
cted AG.
agen
be separated. When repairing, renew the complete component.
6.2.1 Removing and installing front interior

light and reading light

olks
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Removal wedge -VAS 3409-horis nte
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rrectness
Note
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cial p
f inform
mer
atio
m

o
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driver).
thi
te
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Removing:
um
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fo
en
ng
t.
yi
Co
Cop py
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Carefully lever trim out of interior light using removal wedge -
ht
pyri by
Vo
VAS 3409- or screwdriver -arrow-.
co lksw
by
cted agen
Prote AG.

Take the interior light out of the headliner console.


Installing:
AG. Volkswagen AG d
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6.2.2 Removing and installing sunroof switch Vo gu
d by ara
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-E8- aut
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Removing:
ce
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nl
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
stallation frame.
in t
or
his
ate
Installing:
do
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or

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en
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6.2.3 Replace front interior light -W1-


Note

driver).
Removing:
Carefully lever lens for interior light
olkout
swausing removal wedge
-VAS 3409- or screwdriver w en AG. V
ag-arrow-.
gen AG
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, is n
h re
hole
spec
es, in part or in w
t to the co
Press contact -1- of light to side -arrow- and remove festoon

bulb -2- with the contact from the interior light.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
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by c lksw
cted agen
Prote AG.

Pull contact -arrow- off defective festoon bulb.

Fit the contact to the new festoon bulb (12 V, 10 W).
Installing:
AG. Volkswagen AG d
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pt
6.2.4 Left centre reading light -W39- and right
an
d
itte
y li
erm
centre reading light -W40-
ab
ility
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is n
Removing:
h re
ole,
spec
t to the co
Turn bulb holder -arrows- of the defective reading light for 90
to the left.
Take the holder with the bulb out of the reading light.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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cum
r
fo
en
ng
Pull glas base bulb carefully out of the holder.

t.
yi Co
Cop py
Renew glas base bulb (12 V, 5 W).
ht. rig
rig ht
py by
co Vo
Installing:
by lksw
cted agen
Prote AG.
6.3 Rear interior and reading light (vehicles

without ATAS)
The following components are integrated in the rear interior light
and reading light:
Rear left footwell light -W45-
Rear left reading light -W11-
Rear right reading light -W12-

Note
interior light and reading light are connected together
AG. Vo and
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6.3.1 Removing and installing rear interior au
tho eo
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c
ss
and reading light (vehicles without
ce
e
nl
pt
ATAS)
du
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erm
ab
Removing:
ility
ot p
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, is n
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hole
Release locking lugs -arrows- and take trim with lens off inte
spec
rior light and reading light.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
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Release locking lugs -arrows- and remove interior light and

p
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or
reading light from the headliner.

f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Installing:

6.3.2 Renewing rear interior and reading light

bulbs (vehicles without ATAS)
Removing:
Release locking lugs -arrows- and take trim with lens off inte
rior light and reading light.
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Pull glas base bulb carefully out of the holder -arrows-.

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ab
pe
Renew defective glas base bulb (12 V, 5 W).
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ot
wit
, is n
Installing:
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
6.4 Rear interior and reading light (vehicles

m
a
com
ti
with ATAS)
on in
r
te o
thi
The following components are integrated in the rear interior light

s
iva
do
and reading light:

r
rp
cum
fo
en
g
Rear left footwell light -W45-

n
t.
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Rear left reading light -W11- ht. rig
rig ht
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Rear right reading light -W12-
by c lksw
cted agen
Prote AG.
Anti-theft alarm ultrasonic sensor -G209-
Note
The switches -1- of the reading lights are integrated in the rear
interior and reading light and cannot be renewed separately.
The anti-theft alarm ultrasonic sensor -G209- -2- cannot be
renewed separately.
The anti-theft alarm ultrasonic sensor -G209- , comprising four
individual sensors -2-, leads and a control element on the back
of the interior and reading light, must not be moved from its
predefined position.

6.4.1 Removing and installing rear interior

and reading light (vehicles with ATAS)
Note
If a rear interior and reading light is removed, the ATAS must

be deactivated page 277 .
The switches -1- of the reading lights are integrated in the rear
interior and reading light and cannot be renewed separately.
The anti-theft alarm ultrasonic sensor -G209- -2- cannot be
renewed separately.
Removing:
Pull the entire complete trim -1- (including lens and reflectors)
-arrows- vertically downwards and out from the interior and
reading light.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
Press both locking tabs -2- in -direction of arrow A- and take

the complete interior and reading light -1- in spec
-direction of arrow B- off the headliner. t to the co

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
Unlock connectors -1- and -2- and pull both connectors off.
iv
o
pr
cum
r
fo
Installing:
en
ng
t.
yi Co
op
Install in reverse order of removal. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

6.4.2 Renewing rear interior and reading light

bulbs (vehicles with ATAS)
Note
If a rear interior and reading light bulb is renewed, the ATAS

must be deactivated page 277 .
Removing: AG. Volkswagen AG d

agen oes
lksw not
Switch off the ignition and all electrical consumers. d by
Vo gu
ara
ise nte
or eo
h
Pull the entire complete trim -1- (including autlens and reflectors) ra
s c
vertically downwards and out from the interior and reading
s
ce
le
light.
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Pull the glass base bulb to be removed (12 V, 5 W) -1- from

the holder.
nform
ercia
Installing:
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
6.5 Removing and installing front passenger

side illuminated vanity mirror -W14- and
driver side illuminated vanity mirror -
W20-

Note

srewdriver).
The removal and installation of both lights is the same so that
only one light is described.
Removing:
Lever light carefully out of the roof trim using removal wedge
. Volkswagen AG
-VAS 3409- or a screwdriver. swa
gen AG does
olk not
yV gu
edb ara
ris nte
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co

Renew bulb:
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Press contact -1- of the light in direction of arrow and take

festoon bulb -2- out of the socket.
Renew festoon bulb (12 V, 5 W).
Installing:
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
6.6 Removing and installing garage door ss a c
ce
e
operating unit -E284-
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
The garage door operating unit -E284- is located in the sun
hole
spec
visor on the driver side.
es, in part or in w
t to the co
The sun visor and the garage door operating unit -E284- may
only be replaced together.
rrectness of i
Remove the sun visor on the driver side with garage door op
l purpos
erating unit -E284- -1- General body repairs, interior; Rep.

Gr. 68 ; Removing and installing sun visor
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

7 Lights and switches in centre console
7.1 Removing and installing TCS and ESP

button -E256-
Removing:
Take bellow carefully off centre console -arrows-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
Unbolt securing bolts -arrow-.utho
or
a ac
ss
Take mounting frame with ashtray out of the centre console.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


stallation frame.
Installing:
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Lights and switches in centre console 273

8 Horn
8.1 Removing and installing treble tone horn

-H2- and bass tone horn -H7-
Note
The treble tone horn -H2- and the bass tone horn -H7- are
controlled in parallel from the onboard supply control unit -
J519- .
The procedure for removal and installation of treble tone horn
-H2- and bass tone horn -H7- is the same and is therefore
described for just one horn.
The horns are installed to the left and the right of theAGlongitu
. Volkswagen
dinal members. wage
n AG do
es n
Volks ot g
by ua
ed ran
Removing: oris tee
th or
au ac
ss
ce
e
nl
pt
Remove front bumper General body repairs; Rep. Gr. 63 ;
du
an
itte
Front bumper
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
Unscrew securing bolt -arrow- and remove horn.

n
c
in t
or
his
e
Installing:
at
do
priv

um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
8.2 Checking treble tone horn -H2- and bass

tone horn -H7-
The horns ( treble tone horn -H2- and bass tone horn -H7- ) can
be checked using final control diagnosis from the onboard supply
control unit -J519- .

9 Immobilizer
The vehicle is equipped with an immobilizer of the 4th generation.
Modifications by comparison with the immobilizer of the 3rd gen
eration:
An adaptation of components of other group marks to Volks
wagen vehicles is no longer possible.
Vehicle keys are preprogrammed with a base code by the
manufacturer. This base code includes a specific manufactur
ers code. It is only possible to learn a key of a vehicle if they
are programmed with the right manufacturers code.
The immobilizer is equipped with self-diagnosis
agen which
AG. Volkswamakes
gen AG fault
does
finding easier. o lksw not
yV gu b ara
ed
For fault finding, use the vehicleris diagnosis, testing and informa nte
tho e
tion system -VAS 5051A- s auin guided fault finding mode. or
ac
s
ce
9.1 Immobilizer control unit -J362-
le
un
pt
an
d
itte
y li
The immobilizer control unit -J362- is integrated in the dash panel
erm
ab
insert. If the control unit is defective the complete dash panel in
ility
ot p
sert must be renewed.
wit
is n
h re
ole,
Renewing dash panel insert page 150 .
spec
9.2 Immobilizer reader coil -D2-
t to the co
The immobilizer reader coil -D2- is joined to the ignition switch
and cannot be renewed individually.
Removing and installing ignition switch page 231 . rrectness
9.3 Ignition key

o
cial p
f inform
Removing and installing the ignition key battery with radio re

mer
mote control General Body Repairs, Exterior; Rep. Gr. 57 ;

atio
m
Central locking; Removing and installing battery for the (fold

o
n
c
i
or
ing) main key with radio remote control .

thi
te
sd
va
Removing and installing the radio container (transmission unit

i
o
pr
cum
r
for radio-controlled central locking) for the ignition key Gen

fo
en
ng
eral Body Repairs, Exterior; Rep. Gr. 57 ; Central locking;

t.
yi Co
op
Removing and installing battery for the (folding) main key with C py
t. rig
radio remote control .
gh ht
pyri by
Vo
o
by c lksw
9.3.1 Ignition key - change code transponder
cted agen
Prote AG.
It is not possible to replace the change code transponder in the

ignition key.
The entire key must always be replaced if the change code trans
ponder is found to be defective.
Note
If an ignition key is replaced or an additional ignition key is

required, the new ignition key must always be adapted to the
immobilzer page 276 .
If the radio container (transmission unit for radio-controlled
central locking) of the ignition key is also replaced, it must be
adapted to the comfort system page 276 .
9. Immobilizer 275
9.3.2 Adapting ignition keys to the immobilizer

Connect Vehicle Diagnosis, Testing and Information System
-VAS 5051A- page 281 .
Body
Electrical System
Immobilizer
Immobilizer functions agen
AG. Volkswagen AG d
oes
olksw not
Adapting ignition keys byV gu
ara
ed
ris nte
o eo
9.3.3 Adapting ignition keys to the comfort
h
aut ra
ss c
system
ce
e
nl
pt
du
an
itte
y li
erm
ab
-VAS 5051A- page 281 .
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Body
rrectness of i
l purpos

Comfort system
nf
ercia
or
Comfort system central control unit functions
m
m
atio
m
J393 - Adapting / testing keys with radio remote control

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

10 Anti-theft alarm system (ATAS)
Note
The functions of the ATAS are integrated into the central control
unit for comfort system -J393- .
The anti-theft alarm system is equipped with self-diagnosis which
makes fault finding easier.
en AG. V
olkswagen AG
ag does
ksw not
y Vol gu
b ara
ed
Note thoris nte
eo
au ra
c
ss
Once the anti-theft alarm system has been triggered, the alarm
ce
e
nl
source that has been stored in the convenience system central
pt
du
an
control unit -J393- can be interrogated page 298 .
itte
y li
erm
ab
ility
ot p
10.1 Activating and deactivating anti-theft
wit
, is n
h re
alarm system
hole
spec
es, in part or in w
Activating anti-theft alarm system:
t to the co
The anti-theft alarm system is switched on automatically when the
vehicle is locked. The system is then immediately armed.
rrectness of i
l purpos
Note
nform
ercia
Completely close all windows and doors before locking the vehi
cle to prevent the anti-theft alarm system triggering an unneces
m
at
sary alarm.
om
ion
c
in t
or
his
e
Deactivating anti-theft alarm system:

at
do
priv
cum
The system is deactivated when the vehicle is unlocked using

for
en
g
the radio remote control key or

n
t.
yi Co
Cop py
when the ignition is switched on.
t. rig
gh ht
pyri by
Vo
o
Unlock the car mechanically (emergency open) by c lksw
cted agen
Prote AG.
Unlock the driver door.
The anti-theft alarm system remains active, although no alarm is
triggered.
Switch ignition on within 15 seconds.
Note
If you do not switch on the ignition, the alarm will trigger after 15
seconds.
10. Anti-theft alarm system (ATAS) 277

When the ignition is switched on, the electronic immobilizer de

tects a valid vehicle key and deactivates the anti-theft alarm
system.
10.2 Removing and installing anti-theft alarm

ultrasonic sensor -G209-
The anti-theft alarm ultrasonic sensor -G209- , comprising 4 indi
vidual sensors -2-, leads and a control element on the back of the
interior and reading light, cannot be replaced individually, the en
tire rear interior and reading light must be replaced.
Removing and installing rear interior and reading light (vehi
cles with ATAS) page 268 .
10.3 Removing and installing vehicle inclina

tion sender -G384-
The vehicle inclination sender -G384- -arrow- is located under the
dash panel right behind the front passenger airbag.
AG. Volkswagen AG d
Note ksw
agen oes
not
ol
byV gu
ara
d
The anti-theft alarm system must be deactivated before
orise
the send nte
eo
er is removed page 277 . aut
h
ra
c
ss
ce
le
un
Removing:
pt
an
d
itte
y li
rm
ab
pe
ignition key.
ility
ot
wit
, is n

h re
hole

installing glove compartment; Removing . spec
es, in part or in w
t to the co
Unscrew the securing bolts -1- and remove vehicle inclination

sender -G384- from the bracket.
rrectness of i
Release the connector -2- and pull it away from the vehicle
l purpos
inclination sender -G384- .

Installing:
nform
ercia

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op py
10.4 Central locking and anti-theft alarm sys
. C rig
ht ht
rig by
py
tem aerial -R47-
co Vo
by lksw
cted agen
Prote AG.
Note


tions
The central locking and anti-theft alarm system aerial -R47- is laid
from the central locking and anti-theft alarm system aerial -J393-
to the A-pillar (driver side) in the main wiring loom.
Note
The antenna cannot 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- .
10.5 Alarm horn -H12-

The alarm horn -H12- is located on the right of the A-pillar in the
wing.
10.5.1 Removing and installing the alarm horn

-H12-
Drill -VAS 5134- AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Twist drill 6 mm
rrectness of i
Pop rivet pliers -VAS 5072-

l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
The anti-theft alarm system must be deactivated before the alarm

horn is removed page 277 .
Removing:
ignition key.
10. Anti-theft alarm system (ATAS) 279

Remove front right wheel housing liner General body re

pairs, interior; Rep. Gr. 66 ; Wheel housing liner; Removing
and installing front wheel housing liner; Removing .
en AG. V
olkswagen AG
ag does
ksw not
Drill out both pop rivets -arrows- using drill Vol
by -VAS 5134- and gu
ara
6 mm twist drill. ris
ed
nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Pull alarm horn -H12- -1- in -direction of arrow- out of the
rrectne
aperture in the bodywork.
Pull connector off -2-.
ss o
cial p
f
Installing:
inform
mer
atio
m
Note
o
n
c
i
or
n thi
te
sd
a
Remove all metal particles caused during the drilling.

iv
o
pr
cum
r
fo
en
ng
Perform measures for corrosion protection General Infor

t.
yi Co
op
mation; Body Repairs, General Body Repairs . C py
t. rig
gh ht
yri by
Fit connector to the alarm horn -H12- . cop Vo
by lksw
cted agen
Prote AG.
Insert clip -2- of alarm horn -H12- -3- into the aperture in the
bodywork -1-.
Secure alarm horn -H12- with pop rivet pliers -VAS 5072- .
10.5.2 Checking alarm horn -H12-

The alarm horn -H12- can be tested using final control diagnosis
from convenience system central control unit -J393- .

97 Wiring
1 Vehicle Diagnosis, Testing and Infor
mation Systems
WARNING
During testing or measuring operations using a vehicle di

agnosis information system, there is a risk of serious or
even fatal injury!
If the vehicle diagnosis information system is lodged in the
activity area of an airbag during a testing or measuring
operation, a triggered airbag can result in serious or even
fatal injury! gen AG
. Volkswagen AG
d a oes
lksw not
During testing and measuring
db
y V operations, work with a sec
o gu
ara
ond person who can operate
ris
e the vehicle diagnosis infor nte
ho of the rear seats!
mation system fromautone
eo
ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
All working instructions described, such as modifications, cod
h re
ole,
ing etc. can be carried out using the vehicle diagnosis, testing
spec
and information system -VAS 5051A- and the vehicle diagno
sis and service information system -VAS 5052- .
t to the co
All working instructions can be found in guided fault finding
and guided functions.
Additional information: rrectness o
Self-study programme No. 202 ; Vehicle Diagnosis, Testing

cial p
f in
and Information System VAS 5051

form
mer
atio
Self-study programme No. 256 ; VAS 5052

om
n
c
Self-study programme No. 294 ; Online connection of the VAS

or
n thi
e
5051
t
sd
iva
o
pr
Connecting Vehicle Diagnosis, Testing and Information Sys

um
r
fo
en
ng
tem -VAS 5051A- page 281 .

t.
yi Co
Cop py
Connecting vehicle Diagnosis, Testing and Information Sys
t. rig
gh ht
yri
tem -VAS 5052- page 282 . p by
o Vo
by c lksw
cted agen
1.1 Connecting vehicle Diagnosis, Testing
Prote AG.
and Information System -VAS 5051A-
Note
Observe the latest operating instructions for vehicle diagnosis,

testing and information system -VAS 5051A- , which are dis
played after selecting the Administration and Operating Man
ual buttons.
1. Vehicle Diagnosis, Testing and Information Systems 281


5051A-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
Diagnosis lead -VAS 5051/6A- (5 m)
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
Diagnosis lead -VAS 5051/5A- (3 m)

o
n
c
i
or
n thi
te
sd
iva
o
r
Note
p
cum
r
fo
en
ng
t.
yi Co
Only these leads are to be used for diagnosis, as they are the only Cop py
ones fitted with CAN lines and therefore allowing CAN diagnosis
t. rig
gh ht
yri
and/or CAN communication.
p by
o Vo
by c lksw
cted agen
Prote AG.
Connecting Vehicle Diagnosis, Testing and Information System -
VAS 5051A- :
Apply handbrake.
On vehicles with automatic gearbox, move selector lever to
position P or N.
On vehicles with manual gearbox, move gear stick to neutral
position.
With the ignition switched off, connect vehicle diagnosis, test
ing and information system -VAS 5051A- using diagnostic lead
-VAS 5051/6A- to diagnostic interface -arrow- in vehicle.
Switch ignition on.
Switch off all electrical consumers.
Note
Any additional vehicle diagnosis, measuring and information sys

tems and/or vehicle diagnosis and service information systems
are connected in the sequence described above.
282 Rep. Gr.97 - Wiring

2 Removing and installing fuse holder
2.1 Removing and installing fuse holder on

left of dash panel
AG. Volkswagen AG d
agen oes
Noteolksw not
y V gu
d b ara
rise nte
o
When removing and aut installing components in visual area (con e or
h
ac
nectors, covers,sstrims etc.) apply a commercial adhesive tape
ce
le
un
pt
driver).
an
d
itte
y li
rm
ab
pe
ility
ot
Caution
wit
, is n
h re
hole
spec

es, in part or in w

t to the co
Removing:
rrectness of i

l purpos
Remove storage compartment on driver side General body

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Removing and installing fuse holder 283

Remove lateral cover -1- out of the dash panel, by inserting

the removal wedge -VAS 3409- or a screwdriver in the recess
-2- and lever off cover -1- in -direction of arrow-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Take fuse assignment card -1- out of fuse holder -2-.
nf
ercia
Remove securing bolts -arrows- and take fuse holder -1- out
or
as far it is possible (depending on cable length).
m
m
atio
om
Installing:
n in
or c
thi
e

t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3 Removing and installing relay carrier
3.1 Removing and installing relay carrier

wage
with
by
Volkssafety cut-out on left es n
oof
t gu dash panel
ara
ed nte
ris
tho e or
au Caution ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Removing:
h re
hole
spec
es, in part or in w
t to the co
Unscrew bolts -arrows- of the bracket.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
Pull relays -arrows- out of the relay carrier.
co Vo
by lksw
cted agen
Prote AG.
Note
The relay number depends on vehicle equipment.
Clip locking lugs in -direction of arrow- outwards and then

press the connector -1- through the relay carrier.
3. Removing and installing relay carrier 285

Unlock locking lug -1- of relay carrier in -direction of arrow- and

take relay carrier off.
Installing:
Clip connectors into the relay carrier first.
Fit relay carrier -2- into guide -1- and engage relay carrier.
3.2 Removing and installing relay carrier on

onboard supply control unit, on left of
dash panel
AG. Volkswagen AG d
agen oes
ksw not
Note by
Vol
gu
ara
ed
ris nte
o eo
The onboard supply control unit -J519- and the
aut relay carrier
h
ra
attached to the onboard supply control unit, on left of dash ss c
ce
le
panel form one unit and cannot be separated.

un
pt
an
d
itte
If the onboard supply control unit -J519- is to be replaced, first

y li
rm
ab
carry out the procedure

pe
ility
5.1.2 Coding onboard supply control unit J519 ,

ot
wit
, is n
page 293 to read out the stored codes.

h re
hole
spec
Removing:
es, in part or in w
t to the co
ignition key.
rrectness of i
Remove cover, footwell, on driver side General body re

pairs, interior; Rep. Gr. 68 ; Compartments, covers and trim .
l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
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by c lksw
cted agen
Prote AG.

Move locking bar -1- of the relay carrier connectors on onboard

supply control unit, on left of dash panel in
-direction of arrow A-.
Move locking bar -2- of the connectors of the on onboard sup
ply control unit -J519- in -direction of arrow B-.
Note
The connectors of the onboardAG. Volksupply

swagen control unit -J519- and the
relay carrier on onboardagensupply controlAunit, eson
notleft of dash panel
G do
lksw
may only be pulled
y V off if the locking bar is set to position OPEN.
o gu
db e
ar an
ris tee
tho o
Remove
ss
all connectors of the onboard supply
au - controlr aunit
c
J519- and the relay carrier on onboard supply control unit, on
ce
e
nl
left of dash panel.
pt
du
an
itte
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erm
ab
ility
ot p
Note
wit
, is n
h re
The connector number depends on vehicle equipment.
hole
spec
es, in part or in w
t to the co
Unclip onboard supply control unit -J519- and relay carrier on
onboard supply control unit, on left of dash panel out of the
locking device -arrows C-.
Pull onboard supply control unit -J519- and relay carrier on rrectness of i
l purpos
onboard supply control unit, on left of dash panel downwards

and in opposite direction of travel out of the bracket.
nf
ercia
Installing:
orm
m

atio
om

n in
or c
thi
te
sd
iva
o
r
Note
rp
cu
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The locking bars may only be set to CLOSE when all connectors
Cop py
are fitted correctly.
t. rig
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pyri by
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cted agen
Prote AG.
3. Removing and installing relay carrier 287

4 Electronics boxes agen

AG. Volkswagen AG d
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4.1 Removing and installing electronics box ho eo
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on left in engine compartment s
ce
le
un
pt
an
d
itte
y li
Caution
erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
Removing:
rrectne
Release clips -1- in -direction of arrow- and take cover of elec
tronics box -2- off upwards.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Remove hexagon nuts -1-.

Open -arrows- covers -2- of cable guides on electronics box.
Remove wiring from stud connections.
Unclip wiring from cable guides.

Remove central securing screw -arrow- from electronics box

-1-.
Note
When the central securing screw -arrow-, the electronics box -1-
is pushed upwards off the electronics box mounting.
Pull electronics box -1- upwards off electronics box mounting.
Note
For removal of the flat contact housing -1-, the air filter (on vehi
cles with diesel engine only), the battery and the battery console
must be removed.
Remove air filter housing, if necessary.

Remove battery page 29 .
AG. Volkswagen AG d
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olksw not
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tho eo
au ra
ss c
ce
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un
pt
an
d
itte
y li
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ab
pe
ility
ot
wit
Remove securing bolts -arrows- of battery console -1-.

, is n
h re
hole
Take battery console -1- out of vehicle.

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Electronics boxes 289

Press tabs apart on bracket of electronics box -arrows B- and

slide flat contact housing -1- sidewards -arrow A- out of brack
et 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.
Unscrew securing nuts -arrows- of bracket from electronics

box -1-.
AG. Volkswagen AG d
agen oes
ksw not
Note byV
ol
gu
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o eo
Whether the additional relayaut carrier is installed depends on the
h
ra
vehicle equipment. ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
Pull bracket of electronics box -1-, upwards off studs as far as

es, in part or in w
relay carrier cables allow.

t to the co
Unclip relay carrier -1- sideways out of bracket of electronics

box -2-.
rrectness of i
Take bracket of electronics box -2- out of vehicle.

l purpos
Installing:
nform
ercia

m
at
om

on
c
in t
page 307 .
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Mount the cover -2- on the electronics box and push the 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.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Electronics boxes 291

5 Control units
AG. Volkswagen AG d
agen oes
olksw not
5.1 Onboard supply control unit -J519- ised byV gu
ara
nte
or eo
h
aut ra
ss c
Note
ce
le
un
pt
an
d
itte
y li
The onboard supply control unit -J519- and the relay carrier
erm
ab
attached to the onboard supply control unit, on left of dash
ility
ot p
panel form one unit and cannot be separated.
wit
is n
h re
ole,
spec
t to the co
tions
rrectne
ss
The onboard supply control unit -J519- is responsible for the fol
o
cial p
f
lowing in the vehicle:
inform
mer
Electrical load management
atio
om
Exterior light control
n
c
i
or
n thi
e
Turn signal control

t
sd
iva
o
pr
cum
r
Rear window wiper

fo
en
ng
t.
yi Co
Heated rear window . Cop py
rig
ht ht
rig
Terminal control py by
co Vo
by lksw
cted
Surround lighting
agen
Prote AG.
Terminal control
Dimmers, instrument lighting
Fuel pump presupply
Alternator stand-by
Horn
The following functions can be adapted:
Deleting learning values and setting standard adaptation val
ues
Adjusting period for coming home function (depending on
equipment)
Adjusting period for leaving home function (depending on
equipment)
Adjusting rear window heating On time
Switching on and off footwell lighting
Switching on and off motorway signaling
Adjusting load management
Adjusting activation time for headlight cleaning system
page 294

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
Note thor eo
au ra
ss c
The above adaptations can only be carried out in conjunction
ce
le
un
pt
with certain equipment configurations.
an
d
itte
y li
The Motorway signaling, comfort signaling, or tap signal
erm
ab
ility
ing means that one touch of the turn signal lever will activate
ot p
the turn signals (1-5 times) (turn signal cycles).
wit
is n
h re
ole,
spec
t to the co
5.1.2 Coding onboard supply control unit J519 ,
page 293 , so that access can be gained to the codes stored
within.
rrectne
ss
The onboard supply control unit -J519- is equipped with self-di
o
cial p
f
inform
mer
atio
m

o
n
c
i
or
n
5.1.1 Removing and installing onboard supply
thi
te
sd
va
control unit -J519-

i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
Note
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
5.1.2 Coding onboard supply control unit J519 , page 293 ,
so that access can be gained to the codes stored within.
Removing:
The removal of the onboard supply control unit -J519- corre
sponds to the removal of the relay carrier on onboard supply
control unit, on left of dash panel page 286 .
Installing:
The installation of the onboard supply control unit -J519- corre
sponds to the installation of the relay carrier on onboard supply
control unit, on left of dash panel page 286 .
5.1.2 Coding onboard supply control unit -

J519-
-VAS 5051A- page 281 .
Body
Electrical System
Onboard supply control unit
Onboard supply control unit functions
Code control unit
5. Control units 293

5.1.3 Modifying headlight cleaning system

The active time of the headlight cleaning system can be variably
adjusted to between 0 and 12.75 seconds.
Body
Electrical System
AG. Volkswagen
01 - On Board Diagnostic
lksw
capable
agen systems AG does n
o ot g
yV ua
Onboard supplyriscontrol
ed
b
unit ran
tee
tho or
Onboard supply
sa
u control unit functions ac
s
ce
le
Modifying headlight cleaning system

un
pt
an
d
itte
5.2 Data bus diagnostic interface -J533-

y li
rm
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
Additional information: t to the co

tions
rrectness of i
l purpos
nform
ercia
The diagnosis interface for data bus -J533- (gateway) is a sepa

m
rate control unit. It has the following functions in the vehicle:

a
com
tion in
Responsible for exchange of data between CAN data bus sys

r
te o
thi
tems drive train CAN data bus, convenience CAN data bus
s
iva
do
and Infotainment CAN data bus

r
rp
cum
fo
Converts diagnostic data from CAN data bus systems to COM

en
ng
t.
yi
wire and vice versa. In this way, data can also be used by the
Co
Cop py
the vehicle diagnosis, testing and information system -VAS
t. rig
gh ht
yri
5051A- p by
co Vo
by lksw
cted agen
Prote AG.
Note
If the data bus diagnostic interface -J533- is to be removed, first

5.2.1 Renewing data bus diagnostic interface J533 ,
page 295 , so that access can be gained to the codes stored
within.

The data bus diagnostic interface -J533- is equipped with self-
diagnosis, which is designed to ease fault finding.

5.2.1 Renewing data bus diagnostic interface

-J533-
-VAS 5051A- page 281 .
Body
Electrical System
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-
Removing:
agen
Note
AG. Volkswagen AG d
oes
olksw not
V gu
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Before removing
rised data bus diagnostic interface -J533-
ara
nte , it is es
sentialutthat the following work procedure
ho eo
ra
1.1
ss a Renewing dash panel insert, page 150 is carried c out, so
that access can be gained to the codes stored within.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ignition key.
ility
ot p
wit
, is n
Remove cover, footwell, on driver side General body re

h re
pairs, interior; Rep. Gr. 68 ; Compartments, covers and trim .

hole
spec
es, in part or in w
Release connector -1- and pull connector off data bus diag
t to the co
nostic interface -J533- -2-.

Push securing pins -3- together -arrows- and pull out of holes.
rrectness of i
Installing:
l purpos

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
5.3 Central control unit for convenience sys

en
ng
t.
yi Co
op
tem -J393-
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note

tions

The convenience system central control unit -J393- is responsible
for the following in the vehicle:
Sliding/tilting sunroof control (release instruction)
Power window control (release instruction)
AG. Volkswagen AG d
Central locking control lksw
agen oes
not
o
yV gu
Anti-theft alarm system control rised b ara
nte
ho eo
Radio-wave receiver aut ra
ss c
ce
le
Rear lid lock
un
pt
an
d
itte
Comfort operation
y li
erm
ab
ility
Some of the above functions can be adapted page 298 .
ot p
wit
is n
h re
ole,
spec
The convenience system central control unit -J393- is equipped
with self-diagnosis, which is designed to ease fault finding.
t to the co
rrectne
5.3.1 Removing and installing convenience
s
system central control unit -J393-
s o
cial p
f inform
Removing:
mer
atio
om
n
ignition key.
c
i
or
n thi
te
sd
iva
o
r

p
cum
r
fo
en
ng
t.
yi Co
op
Pull locking lug -1- off convenience system central control unit C py
ht. rig
-J393- bracket in -direction of arrow- and move the conven rig ht
py by
ience system central control unit -J393- until the recesses
co Vo
by lksw
cted
-2- align with the recesses -3-.
agen
Prote AG.
Note
The connectors may only be unlocked and pulled off if the re

cesses -arrows- of the connectors and the bracket align exactly.
Unlock connectors and pull them off convenience system cen

tral control unit -J393- .
Note
The connector number depends on vehicle equipment.

Unscrew securing nuts -arrows-.

Take bracket off with convenience system central control unit
-J393- .
Volkswagen AG
Pull locking lug -1- in -direction of arrow B- and push conven swagen AG. does
ience system central control unit -J393- -2- out of the bracketby
Vol
k not
gu
ara
in -direction of arrow A-. ris
ed
nte
ho eo
ut
Installing: ss
a ra
c
ce
Installation is performed in the reverse order of installation; when e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Note
l purpos
After installing a new convenience system central control unit

it must be coded page 297 .
nform
ercia
The connectors may only be placed and locked if the recesses

m
-arrows- of the connectors and the bracket align exactly.
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
5.3.2 Coding convenience system central
gh ht
pyri by
Vo
co
control unit -J393-
by lksw
cted agen
Prote AG.

-VAS 5051A- page 281 .
Body
Comfort system
J393 - Coding convenience system central control unit

5.3.3 Adapting convenience system central

control unit -J393-
The following functions can be adapted:
Activating and deactivating single door opening
Activating and deactivating automatic locking above >15 Km/
h
Activating and deactivating automatic unlocking when ignition
key is removed
Activating and deactivating country settings for intelligent
alarm horn
Activating and deactivating battery monitoring system (soun
der) AG. Volkswagen AG d
agen oes
lksw not
Activating and deactivating comfort operation via radio reby V o gu
ara
mote control unit rised
nte
ho eo
ut
Activating and deactivating anti-theft alarm system
ss a - alarm ra
c
delay when driver's door is opened
ce
le
un
pt
an
d
Sensitivity of tilt angle sensor

itte
y li
erm
ab
Sensitivity of interior monitoring system
ility
ot p
wit
is n
h re
-VAS 5051A- page 281 .
ole,
spec
t to the co
rrectne
Body
ss o
cial p
f inform
mer
atio
m
Comfort system
o
n
c
i
or
n
thi
te
sd
iva
J393 - Adapting convenience system central control unit o

pr
cum
r
fo
en
ng
5.3.4 Convenience system central control unit

t.
yi Co
op py
-J393- - Read alarm sources of anti-theft
t. C rig
gh ht
pyri by
alarm system
o Vo
by c lksw
cted agen
Prote AG.
-VAS 5051A- page 281 .
Body
Comfort system
J393 - Read alarm sources of anti-theft alarm system

5.4 Trailer detector control unit -J345-

The trailer detector control unit -J345- -arrow- is located behind
the left side trim in the luggage compartment.
Note

tions
Note
The Golf currently features only control units manufactured by

Westfalia.
To check the control unit use plug socket tester -V.A.G 1537/ gen AG
. Volkswagen AG
A- olks
wa does
not
5.4.3 Final control diagnosis trailer detector controleunit
db
yV gu
ara
J345 , page 301 . tho
ris nte
eo
au ra
c
ss
The trailer detector control unit -J345- etects from a power draw
ce
e
nl
pt
of minimum 5 W4) the trailer operation and transfers this infor
du
an
itte
mation to various control units via the CAN databus.
y li
erm
ab
ility
The trailer detector control unit -J345- is supplied with information
ot p
wit
(light control) from the onboard supply control unit -J519- and
, is n
h re
convenience system central control unit -J393- via the CAN.
hole
spec
4) At least the turn signal and brake light must be switched on, in order to detect
es, in part or in w
trailer operation.
t to the co
The trailer detector control unit -J345- is equipped with self-diag
rrectness of i
nosis, which is designed to ease fault finding.
l purpos
nform
mercia
5.4.1 Removing and installing trailer detector at

om
ion
control unit -J345-

c
in t
or
his
ate
do
riv

p
cum
for

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Removing:
ignition key.
Remove left side panel trim in luggage compartment Gen
ling load and luggage compartment trim; Trim, luggage
compartment, sidewards .
Release connectors -2- and pull off trailer detector control unit
-J345- .
Note
The connector number on the trailer detector control unit -J345-

shown in the figure depends on vehicle equipment and may vary.
Remove securing bolts -1- and take trailer detector control unit
-J345- with the bracket out of the vehicle.
Remove securing bolts -arrows- and take trailer detector con

trol unit -J345- off bracket.
Installing:
doing this, note the following: . Volkswag AG en AG
w agen does
Tighten threaded connections to specified
yV
olks torque settings not
gu
page 307 . ise
d b ara
nte
r
ho eo
aut ra
ss c
Note
ce
e
nl
pt
du
an
itte
y li
After installing a new trailer detector control unit -J345- it must be

erm
ab
coded page 300 .

ility
ot p
wit
, is n
h re
hole
5.4.2 Coding trailer detector control unit -

spec
es, in part or in w
J345-
t to the co

-VAS 5051A- page 281 .
rrectness of i

l purpos

nf
ercia

rm
m
atio
m
Body
o
n in
or c

thi
te
sd
iva

r
rp
cu
o
m
f
en
ng
Trailer detector
t.
yi Co
Cop py
Function
t. rig
gh ht
pyri by
Vo
o
Coding trailer detector control unit
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes Jetta 2005 , Bora 2006
olksw not
V
ed by gu
ara Electrical System - Edition 05.2005
ris nte
tho e or
5.4.3 Final control diagnosis trailer detector
ss
au ac
ce
le
control unit -J345-
un
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
The trailer detector control unit -J345- detects from a power
hole
spec
draw of minimum 5 W 4) the trailer operation.
es, in part or in w
t to the co
To check use plug socket tester -V.A.G 1537/A- .
rrectness of i
Plug socket tester -V.A.G 1537/A- 5)
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5) After a few minutes the plug socket tester -V.A.G 1537/A- gets to hot and
switches off automatically. After a cooling period the plug socket tester -V.A.G
1537/A- works again perfectly.
Connect the plug socket tester -V.A.G 1537/A- .

-VAS 5051A- page 281 .
Body
Trailer detector
Function
Trailer detector control unit - Final control diagnosis

6 Wiring harness and connector re

pairs
6.1 Safety instructions
Caution
For repair work on airbag and seat belt tensioner wiring har
nesses, only contacts, connectors and wiring designed specif
ically for this purpose may be used Parts catalogue (ETKA)!
Observe country-specific regulations.

Observe vehicle stickers indicating high voltage components.
Before carrying out repairs, discharge residual voltage.
Wires from airbag and belt tensioner wiring harness must only
be repaired using wiring harness repair set -V.A.Gw1978-
agen .
AG. Volkswagen AG d
oe
olks s no
t gu
Operating instructions wiring harness repair
ed
bset
y V -V.A.G 1978- ara
is nte
or
General body repairs interior; Rep. Gr.
au 69
th eo
ra
ss c
6.2 General notes concerning repairs to ve
ce
e
nl
pt
du
an
hicle electrical system
itte
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erm
ab
ility
ot p
Caution
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Observe current notes (also notes concerning removing and
rrectness of i
installing components) in workshop manuals and in the Tech
nical Service Handbook.
l purpos
Yellow wiring and sections of wiring harness wrapped in yellow

nform
tape indicate a prior repair.

mercia
Operating instructions wiring harness repair set -V.A.G 1978-

at
om
ion
c
Before beginning repairs to a wiring harness, first rectify the

in t
or
his
cause of the damage, e.g. sharp edges on a body part, de

ate
do
riv
fective electrical consumer, corrosion.

p
cum
for
Disconnecting the battery earth strap (open circuit) provides a

en
ng
t.
yi
safe working environment for repairs to the electrical system.
Co
Cop py
The battery positive wire need only be disconnected for re ht. rig
rig ht
moval of the battery.
py by
co Vo
by lksw
cted agen
If possible, do not loosen any earth wires from the body (dan
Prote AG.
ger of corrosion).
6.3 Notes on repairs to wiring harness and

connectors
Supplementary notes on repair of CAN bus wiring page 303
Soldering is not permitted for repairs to vehicle wiring.
Never repair any heat-shrink connections. If necessary, lay
wiring parallel to the defective wiring.
Onboard supply wiring harnesses and connectors may only
be repaired using wiring harness repair set -V.A.G 1978- .

Operating instructions wiring harness repair set -V.A.G 1978-

. Volkswagen AG
a gen AG d
Perform wiring harness repairs Vol only with yellow wires. Mark
ksw
oes
not
gu
repair locations with yellow
ed b tape.
y ara
n is tee
or
Shielded wires mustautnot
h
be repaired. In case of damage, they or
ac
must be entirely replaced.
ss
ce
e
nl
pt
du
6.4 Supplementary notes on repair of CAN
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bus wiring
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An unshielded two-wire line -1- and -2- with a cross section of
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0.35 mm2 or 0.5 mm2 is used for CAN bus wiring.
hole
spec
The colour codes of the CAN bus wiring can be gleaned from
es, in part or in w
t to the co
the following table:
Drivetrain CAN, high orange/black
rrectness of i
Convenience CAN, high orange/green
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Infotainment CAN, high orange/violet

CAN Low wire (all) orange/brown
nf
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Perform wiring harness repairs only with yellow wires. Mark
m
m
atio
repair locations with yellow tape.
om
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or c
When repairs are performed, both bus wires must have the
thi
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same length. When wires -1- and -2- are twisted together, the
sd
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twist spacing should be A=20 mm.
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No section of wiring greater than B=50 mm, e.g. in the vicinity

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of heat-shrink sleeves -arrow-, should not be twisted. C py
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6. Wiring harness and connector repairs 303

6.5 Wiring harness repair set -V.A.G 1978-
- Repairs to wiring harnesses

and connectors of the onboard
electrical supply system
should only be carried out us
ing wiring harness repair set -
V.A.G 1978- .
- Included with the wiring har
ness repair set -V.A.G 1978- is
a set of operating instructions,
which provides comprehen
sive information on how to con
duct repairs.
- Further information, e.g. re
moval and installation of parts
and components, appears in
the relevant workshop manual.
AG. Volkswagen AG d
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7 Renewal
yV
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A new repair
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work
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complete aerial wire.

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7.1 General description
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Aerial wires must not be repaired, but if repair is required, they
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must be replaced only by connecting wires and adapter cables
h re
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offered as genuine parts.
spec
es, in part or in w
Replacement parts can be found in the electronic parts cata
t to the co
logue: Special catalogue; Electrical connections; Genuine ac
cessories; Subgroup 35 from illustration No. 035-20.
rrectness of i
These genuine parts are suitable for all aerial wires and wire
diameters which may need to be replaced.
l purpos
No provision has been made for replacement of individual

aerial connectors in the event of repair.
nf
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The wires can be used retroactively for all VW models, with all
m
atio
m
installed aerial wire diameters.

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All adapter and connection wires are suitable for all transmitter thi
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and receiver signals.

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This repair method can also be used for testing or retrofitting.

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7.2 Assembly overview - an aerial wire
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Example: Aerial wire between radio and aerial is defective. The
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following wires are required for the repair:
Prote AG.
1- Adapter cable, to radio connection. Length approx. 30 cm.

2- Connecting wire, available in different lengths.
3- Adapter cable, to aerial connection. Length approx. 30 cm.
7.3 Installing a new aerial wire
Note
Note that the total length of an aerial wire, depending on vehicle

equipment level, can be divided into sections by aerial diversity
control unit, traffic information control unit or aerial amplifier. Only
the defective section of aerial wire must be replaced.
Pull defective aerial wire connections off units.

Determine the routing of the defective aerial wire in vehicle
and measure the total length of the aerial connecting wire to
be replaced.
7. Renewal of aerial wiring 305

The total length of aerial connecting wire is the sum of the length
of adapter cables required -1- and -3- and the connecting wire
-2-.
To determine the length of connecting wire required, subtract
60 cm from the measured total length of aerial connecting wire
-2-. n AG. Volkswagen A ge G do
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Procure the required adapter cables -1- and -3- band y V connect
olk ot g
ua
ing wire -2- at the calculated length as genuine
ris
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tee
parts catalogue (ETKA). ut
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ss
Cut off connectors of defective aerial wire.
ce
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un
pt
an
The remainder of the defective aerial wire remains in the vehicle. d
itte
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Connect adapter cables -1- and -3- to equipment in vehicle.
ility
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Route and secure connecting wire -2- parallel to the old aerial
is n
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wire.
ole,
spec
t to the co
Note
Do not kink or excessively bend aerial wires! The bending radius
rrectne
must not be below 50 mm.
ss
Connect connecting wire to adapter cables.
o
cial p
f inform
Perform a functional check.
mer
atio
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8 Torque settings: Cables

8.1 Torque settings: Electronics box in left
side of engine compartment

Securing nuts -1- M5 (AF 8) 4 Nm
Securing nuts -1- M6 (AF 10) 6 Nm
8.2 Torque settings trailer detector control unit -J345-

Securing bolts bracket to body 2 Nm
Securing bolts control unit to bracket 2 Nm
lkswage es n
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8. Torque settings: Cables 307

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Service

Service Department. Technical Information

94 - Lights, lamps, switches - outside

All rights reserved.

Copyright 2010 Volkswagen AG, Wolfsburg MEX5R005820

1.1 Fundamentals for batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.4 Battery terminal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1 Procedure when checking the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.6 Battery tester with printer VAS 5097 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2 Battery charger VAS 5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.3 Totally discharged batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.1 Disconnecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

11.1 Activating and deactivating cruise control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

90 - Instruments, GCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

2.1 Resetting service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

1 Windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

2 Windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

3 Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

3.1 Assembly overview - headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

94 - Lights, lamps, switches - outside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

6.2 Removing and installing tail light in side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

9.1 Assembly overview - steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

9.2 Removing and installing steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

9.3 Steering column electronics control unit J527 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

9.4 Steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

10 Ignition switch and lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

10.1 Removing and installing steering lock housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

96 - Lights, lamps, switches - inside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

operated switch to block release of rear lid remote E232 . . . . . . . . . . . . . . . . . . . . . . . . . . 252

27 Starter, current supply, CC

Danger of injury! Observe warning notices and safety regula

To prevent damage to the battery and vehicle, the following

1.1 Fundamentals for batteries

Observe Self-study programme No. 234 ; vehicle batteries .

1.2 Types of battery AG. Volkswagen AG d

These batteries are recognised by the removable cell plugs.

topped-up with distilled water as required.

eye provides information concerning the level of the electrolyte

and the charge state of the battery.

1.2.2 Maintenance-free battery

Lead-acid battery, where electrolyte need not be topped-up with

1.2.3 Absorbent glass mat (AGM) battery

Maintenance-free battery with a contained electrolyte.

The battery is sealed and fitted with valves.

Currently gel batteries are only used in motor homes/campers

1.3 Warning notices and safety regulations

1.3.1 Dangers when handling vehicle batter

2 Rep. Gr.27 - Starter, current supply, CC

Untrained personal e.g. apprentices, trainees etc. may

2. - Wear eye protection before commencing work on battery.

3. - Keep children away from acid and batteries.

4. - Disposal: old batteries are classed as hazardous waste. They

may only be disposed of through a suitable collection centre and

only in accordance with respective legislation.

6. - There is a danger of an explosion when working with batteries.

A highly explosive gas is produced when batteries are charged.

system" and in owner's manual.

8. - Battery acid is very caustic, therefore wear eye protection and

leak out of the gas vents of some batteries.

1.4 Battery terminal connection

To prevent damage to the battery terminal clamps and battery

4 Rep. Gr.27 - Starter, current supply, CC

Danger of injury! Observe warning notices and safety regula