GENERAL INFORMATION 9-1 | » General.......-.-+ Voltage and polarity . .. Electrical system safety precautions... Electrical test equipment. . Wiring diagrams, fuses and relays . 9 Electrical System Electrical Troubleshooting . ‘Checking for voltage and ground. To measure voltage . To check for voltage drop . Checking for continuity. ..... Checking for short circuits... To check for short circuit with voltmeter. . . GENERAL ‘This general information group covers a briet description of the principal parts of the electrical system. Also covered here is general electrical system troubleshooting and instructions, ‘onusing Volkswagen wiring diagrams. Voltage and polarity Vokswagen electrical systems aro 12.volt direct curent (0C) negative-ground systems. A voltage regulator controls the outputat the alternator to approximately 13.6 volts. All - cuits ero grounded by director indirect connection to the neg- sive (-) terminal of the battery. A number of ground Connections throughout the car connect the wiring hamess to chassis ground, These circuits are completed by the battery cable or ground strap between the body and the battery nega- tive (terminal. Electrical system safety precautions Piease read the following warnings and cautions before do~ ing any work on your electrical system. WARNING— + Ignition systems operata ina dangerous voltage range that could prove tobe fatal f exposed tor- ‘minals or ive parts are contacted. Use extreme ‘cautlon when working on a vehicle withthe ign tion on oF the engine running. + On cars equipped wih Aibags, special precau- tions apply fo any electrical system testing oF ro- pair. The albag unit is an explosive device and Imust be handled wih extreme care. Botoro Staring any work on an airbag equipped car, ro- fer (0 the warnings and cautions In 69 Seat- bolts, Alrbogs. WARNING — ‘Before operating the starter without staring the on ‘gine (as when making a compression tes, cksabiig- ‘ion eystom as desorbed in28 Ignition Syator. : CAUTION— : + Always sutich the Ignkion off and remove the nagalve (-) bettory cable before removing any Q ‘loctroal components. + Before disconnecting battory be sure to obiain i: rc anti-theft code. “= Connect and disconnect ignition system wiros, ‘multiple connectors, and ignition test equipment Teads only while the ignition i switched oft + Do not cisconnet battery while the engino is run- ring. Never reverse the batiry terminal cannec- fions. Even 2 momentary wrong connection can damage the aternator or electrical components. If ‘the polarity markings onthe batteryare not visible, ‘contr te polarty of battery using a volmeter. + Always remove the battory cables before quick- ‘charging the battery. Never use a quiok-charger 1s a booster for starting the car. Do not exceed 16.5 volts atthe battery. + Many sofd-state moduios operate on very fow current and can be pormanently damaged if ex- posed to static discharge. Always handle the ‘modules using proper static prevention equip- ment and techniques. “Always swich a ost meterto the appropriate func ‘fon and rango before making test connactions. + Disconnect the battery before doing any etectio welding on the car. + Do not wash the engine whio itis running, oF nye the ignition Is switched on. + Do not ty fo start the engine of a car which has ‘been healed above 176°F (80°C), (r exemple, in apaint drying booth) unt alowing it to cool o ‘normal temperature. GENERAL |9-2 GENERAL INFORMATION Electrical test equipment ‘Many ofthe electrical tests describod inthis manual cal for ‘measuring voltage, current or resistance using a digital muli- meter (DMM). DMs are preterted for precise measurements {and for electronics work because they are generally more ac- Curate than analog meters. The DMMis also safe for most sol id stato components whereas an analog moter can damage ‘some components. ‘An LED test light isa sate, inexpensive tool that can be Used to parform many simple electrical ests that would other- wise require a multimeter, The LED indicates when voltage is present between any two test-points in a circuit ‘cauTION— * Choose test equipment carotuly. Use a meter with at least 10 megohm Input impedance, or an LED test ight. An anaiog meter (swing-nosdl) (oF atest fight with @ normal incandescent bub ‘may draw enough current to damage sensiive ‘electronic compenents. + An anaiog meter must not be used to measure __fesistanca on solid stata compononts such as contol units or ime delay relays. + Always disconnect the battery before making ro- sistance (ohm) measurements on the cut. Wiring diagrams, fuses and relays Nearly all parts of the wiring harness connect to compo- ents of the electrical system with keyed, push-on connectors that lock into place. Notable exceptions are the heavy battery ‘cables and the altemator wiring. With the exception ofthe battery charging system, al elect cal power is routed from the lanition switch or the battery through the fuse panel, located in the passenger compartment behind the drivers ieft side knee bar. Fuses pravent excessive ‘current from damaging components and wiring. Fuses are col oF coded to indicate thelr ditferert current capacities. Most re- lays are electro-mechanical switches that operate on low current to switch a high-current circuit on and off ‘The witing diagrams shown in 97 Wiring Diagrams, Fuses, ‘and Relays are organized according to model year and en- sine type, with complete diagrams for each year. ELECTRICAL. TROUBLESHOOTING ELECTRICAL TROUBLESHOOTING Four things are required for current to fow in any elctice Circut: a voltage source, wires or connections to transport the voltage, a consumer or device that uses the electricity, and a, Connection to ground or a return to the voltage source. Moe problems can be found using only @ digital multimeter” {volviohm/amp meter) to check for voltage supply, for breaks _ In the wiring (infinite resistance/no continulty), oF for a path i ‘round that completes the clreit. Electric currents toga! ints low, always moving from the voltage source toward ground. Keeping this in mind, electrica, fauts can be located through a process of elimination. When troubleshooting a complex circuit, separate the circut ints ‘smaller parts. Be sure o analyze the problom, Use the wiring diagrams to determine the most likely cause ofthe problem, ‘Get an understanding of how the cicult works by folowing the ‘lrcuit from ground back to the power source. ‘CAUTION — When mating test connections at connectors and ‘omponents, use care to avoid spreading or dam ‘aging the connectors or terminals. Some slect- cal tests may requito Jumper wires to bypass ‘components. When connecting jumper whes, use ‘blade connectors atthe wie ends that match the sizeof the terminal being tostod. Tho eimai hter- ‘al contacts are easily sproad apart, and this can - ‘aus intermitent or faulty connections that can lead to more problems. Checking for voltage and ground Checking forthe presence of voltage or ground Is usually) the first step in troubieshooting a problem circuit. For exam- Plo, if a parking ight does not work, a check for voltage at the bulb socket will quickly determine ifthe circuit is functioning Properly or ifthe bulb itself is faulty. If voltage and ground are ‘ound at the socket, then the bulb is most likely fault. ‘Another valuable troubleshooting technique is a voltage drop test. This is @ good test to make if current is flowing through the cirouit, but the circuit is not operating correctly. ‘Sluggish wipers or dim headlights are examples of this. A vol- age drop test will help to pinpoint corroded ground strap ora. faulty switch. Normally, there should be less than 1 volt drop _ ‘across mostwires or closed switches. A voltage drop across a ‘connector or short cable should not exceed 0.5 volts{A voltage drop is caused by higher than normal resistance ina circuit. This additional resistance actually decreases or stops the flow of current. Some common sources of voltage ‘drops are faulty wires or switches, dirty or corroded connec- ‘ions of contacts, and loose or corroded ground wires and ‘ground connections. Avottage drop can be checked only when current is flowing through the circuit, such as by operating the stator motor or {uming on the headights. Making a voltage crop test requires ‘measuring the voltage in the circuit and comparing it to what ‘the voltage should be. Since these measurements are usually ‘smal, @ digital voltmeter should be used to encure accurate readings. Ita voltage drop is suspected, turn the crculton and ‘measure the voltage atthe crcult's load. NoTE— +A voltage crop tosis genersily mare accurate than a ‘simple resitanco check because the resistances in- Voivad are often too small to measure with moet ohm ‘meters. For example, a resistance as small 2s 0.02 ohms would result ina 3 Vott crop in @ typcal 150 amp starter rout (150 amps x 0,02 obwms » 3 volts). + Kop in mind that voltage withthe key on and voltage withthe engine cunning ao not the same. With he ig- ition on and the engine off (batlery valage), vaitage should be appraximatoly 12.6 vols. With tho engine running (charging voltage), voltage should be ap- _broximately 14.0 volts. Moasuro votage atthe batiery ‘th the inition on and then with the engine running ‘0 get exact measurements. To measure voltage 1. Set voltage moter to 20V DC scale and connect the negative lead to a reliable ground point on the car. 2, Connect the voltmeter positive lead to the point in the circuit you wish to measure. See Fig. 1. 4. Ifa roading is obtained, there Is voltage at that point in the cult, The voltage reading should not deviate more than 1 volt from the voltage atthe battery the voltage 's less than this, there is probably a fault in the circult, such as a corroded connector or a loose ground wire. To check for voltage drop 1. Connect the digital vollmeter postive lead to positive (#) connector of component to be tested. 2. Connect the volimeter negative lead to the negative (-) ‘connector of the component being tested, See Fig. 2. GENERAL INFORMATION 9-3 Votumetar Fig. 1. Votmeter being uscd to checkcfor voiage. ‘fom Battery Vetmater To] ws 1S) ees Fig. 2. Volmster boing used to check for voiage droo across sich, ‘3. With the power on and the circuit working, the metor shows the voltage drop (the difference between the two points). This value should not exceed 1 volt. NoTE— ‘The maximum voltage drop in an automotive eeu, as ‘recommended by the Society of Automotive Engineers (GAE}, is as follows: 0 Volts for small wire connections; 1.1 Volts for high curent connections; 0.2 Vattsforhigh ‘current cables; and 0.3 Volts for switch or solenoid con- tacts. On fongor wires or cables, the drop may be ‘sight higher. In any case, a voltage drop of more than 1.0 Vott usually ndcates a problem. ELECTRICAL TROUBLESHOOTING9-4 GENERAL INFORMATION Checking for continuity part ofthe car or other ground source, the ccuits shored y . ‘ground. ifthe exposed wiro is lve (postive battery voltage) ‘The continuity test can be used 10 check the basic integrity of the direct current flow to ground will blow a fusé or damageay | Gitcuit or switch. Because most automotive circuits are de- unused cireut. signed to have litle or no resistance, a circuit or part of a clrcult — ‘canbe easly checked for faults using an ohmmeter. An open ci caUTION— ‘uit or a circuit with high resistance will nt allow current to flow. ‘circuit with Ite or no resistance allows current to flow east. ‘CAUTION — 0 notuse an analog (swing-neecto)} ohmmeter to ‘check oreut resistance or eantiuly on any elec- {Wonio(soléstato) components. The internal pow * On acute protected with large fuses (25 amp and ‘Greater, the wires or chet components may be damaged bofre tho fuso blows. Always check for ‘damage belore replacing tases of tis rating. + When replacing blown fuses, use only uses hav {ng the correct rating. Alay’ contirm the corect fuse ratng printed on the fuse pane! cover. er source used in most analog meters can damage solid stato components, Use only 2 high quality digital obmmeter having high input imped To check for short circuit with voltmeter ance When checking elecronic components. 1. Remove the blown fuse from the circu. When checking continuity, the ignition should be off. On c= cats that are powered at all times, the battory should be dis- 2. Disconnect the harness connector trom the clrcuts ‘connected. Using the appropriate wiring diagram, a circuit ean toad or consumer. “a bbe easily tested for fauty connections, wires, switches, re- lays, and engine sensors by checking for continuity. Fig. 3 3, Using a voltmeter, connect the test leads across tho hows a continuty test being made on a brake light switch. fuse terminals. See Fig. 4. Make sure power Is presant Inthe circuit. f necessary, turn the key on. Brake pedal in rest position ‘tom Batery Votreter Brake pedal depressed er st cra ssa] POA het ards er Fig. 8. Breks ight switch belng tested for continuity (battery iscon- 4. If voltage Is indicated at the voltmeter, there is a short ected). With brake pecial in rest position (switch open) there to ground somewhere in the circuit. r 48 no continuity Gifinite ohms). With the pedal depressed {switch closed) there is continuity (zero ohms). 5. If voltage is not indicated, work from the wire harness nearest to the fuse panel and move or wiggle the wires while observing the meter. Continue to move down the Checking for short circuits harness until the meter dieplays a reading. This i the location ofthe short to ground. Ashort circuits exactly what the name implies. The circult 6, Visual inspect he we names at tis port for sry iakes a srt path than wae detgned Tako, The most Common shor tht eauees prions Te aso ground =U. no faut ao vib, carly ten pn he ‘where the insulation on a positive (+) wire wears away andthe harness cover or the wire insulation for further inspec- ‘metal wire Is exposed. When the wire rubs against a metal tion. Repair any faults found. ELECTRICAL TROUBLESHOOTING