Electrical Equipment

2006 Volkswagen Touareg
ELECTRICAL Electrical Equipment
ELECTRICAL
Electrical Equipment
27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL

BATTERY
Battery systems in the Touareg
Different battery systems are installed on the Touareg:
The one-battery concept:
With a battery (with "magic eye" but with no cell plugs) under front left seat.
The one-battery system with auxiliary battery:
With a battery (with "magic eye" but with no cell plugs) under left front seat and also a second battery (a valve-
regulated lead acid battery) in spare wheel recess in luggage compartment. On vehicles with a collapsible spare
tire, there may also be a wet battery with visual indicator ("magic eye").
NOTE:  The auxiliary battery is installed on vehicles with additional equipment,

e.g. auxiliary heater.
The two-battery concept:
NOTE:  The two-battery system with a logical "function separation" in the vehicle
electrical system battery and starter battery is only available for the
Touareg V10 TDI.
With a battery (with "magic eye" but with no cell plugs) under left front seat and also a second battery (a valve-
regulated lead acid battery) in spare wheel recess in luggage compartment. On vehicles with a collapsible spare
tire, there may also be a wet battery with visual indicator ("magic eye").
NOTE:  Observe --> Self Study Program.
Battery types
All instructions and information on this article can be found in the ELECTRICAL EQUIPMENT -
GENERAL INFORMATION .
Warnings and Safety Measures
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Sunday, September 20, 2009 9:06:01
9:05:20 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
Battery post/terminal, handling instructions
BATTERY, CHECKING
Battery, checking
BATTERY, CHARGING
Battery, charging
BATTERY, DISCONNECTING AND RECONNECTING
Battery, disconnecting and reconnecting
CAUTION: Danger of injury! Observe warning notes and safety precautions -->
Warnings and Safety Measures !
Battery (vehicles with one-battery concept), disconnecting and connecting
Battery - dual battery system, disconnecting and reconnecting --> Battery, (vehicles with one-battery concept
with auxiliary battery and two-battery concept), removing and installing.
A maintenance-free battery with "magic eye" is factory-installed beneath left front seat.
Battery, disconnecting:
NOTE:  To disconnect battery, anti-theft warning system must be deactivated -->

Anti-theft Alarm System, activating and deactivating.
 Always ensure the vehicle electrical system is protected by disconnecting
the battery negative (-) terminal (interrupted current flow to ground) prior
to servicing key areas of the electrical system as specified in this article.
Disconnecting the battery positive (B+) terminal must only be performed
as required to remove battery from vehicle, and must only be carried out
after the negative (-) terminal is disconnected. However, observe notes for
connecting battery in any case.
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Sunday, September 20, 2009 9:05:21 AM Page 2 © 2005 Mitchell Repair Information Company, LLC.
 Switch off ignition, switch off all electrical components and remove ignition key.
 Remove left front seat rail cover --> 72 - SEAT - FRAMES .
 Remove left front seat trim --> 72 - SEAT - FRAMES .
Fig. 1: Identifying Seat Slide Rail Screws

Courtesy of VOLKSWAGEN UNITED STATES, INC.
 Remove screws - arrows -.
Fig. 2: Tilting Seat Frame And Seat To Rear

 Tilt seat frame and seat to rear - arrow -.
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Fig. 3: Identifying Bolt & Air Duct

 Remove screw - 1 - and remove air guide - 2 -.
Fig. 4: Identifying Box Clips

 Open battery box clips - arrows - and remove cover.
Fig. 5: Identifying Battery Ground Terminal & Battery Positive Terminal

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 Disconnect negative (-) terminal - 1 - from battery.

 Disconnect positive (B+) terminal - 2 - from battery.
Battery, reconnecting:
Special tools, testers and auxiliary items required
Fig. 6: Torque Wrench V.A.G 1331

 Torque wrench V.A.G 1331/
CAUTION: In order to prevent damage to battery housing, battery terminals must be

placed on battery posts without using force (by hand only).
Battery terminals must not be greased.
Fig. 7: Identifying Battery Ground Line & Battery Positive Terminal

 Refit battery positive (B+) terminal - 2 - on battery positive post.

 Torque positive (B+) terminal fastener to value in table --> Tightening Torques: Battery.
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 Only after the positive (B+) terminal has been secured should negative (-) terminal clamp - 1 - be
installed.
 Torque negative (-) terminal fastener to value in table --> Tightening Torques: Battery.
Fig. 8: Identifying Seat Slide Rail Bolts

 Replace seat frame bolts - arrows - and torque to value in table --> Tightening Torques: Battery.
 Install left front seat rail cover --> 72 - SEAT - FRAMES .
 Install left front seat trim --> 72 - SEAT - FRAMES .
 Perform work steps according to table:
Battery, (vehicles with one-battery concept with auxiliary battery and two-battery concept), removing and installing
A maintenance-free battery with charge indicator ("magic eye") is installed under the drivers seat. In addition,
an Absorbent Glass Mat (AGM) sealed battery is located in the luggage compartment spare wheel well.
Battery disconnecting and reconnecting sequence
CAUTION: Disconnecting and reconnecting batteries on a dual battery system MUST

be performed using the following step-by-step procedure, in the sequence
given. Failure to adhere to the following procedure will result in the
deactivation of Main Battery Switch -E74- and subsequent damage to
electrical system components.
 Disconnect battery under drivers seat.

 Disconnect battery in luggage compartment.
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Battery (under front left seat), disconnecting
NOTE:  To disconnect battery, anti-theft warning system must be deactivated -->

Anti-theft Alarm System, activating and deactivating.
 Always ensure the vehicle electrical system is protected by disconnecting
the battery negative (-) terminal (interrupted current flow to ground) prior
to servicing key areas of the electrical system as specified in this article.
Disconnecting the battery positive (B+) terminal must only be performed
as required to remove battery from vehicle, and must only be carried out
after the negative (-) terminal is disconnected. Observe notes for
connecting battery in any case.

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Fig. 10: Tilting Seat Frame And Seat To Rear



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Fig. 13: Identifying Battery Ground Terminal & Battery Positive Terminal
 Disconnect negative (-) terminal - 1 - from battery.

 Disconnect positive (B+) terminal - 2 - from battery.
Second battery or auxiliary battery, in luggage compartment, disconnecting
Fig. 14: Identifying Auxiliary Battery In Luggage Compartment

 Lift and remove luggage compartment floor cover -arrow-.
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Fig. 15: Identifying Retaining Clips & Nuts (Right Side)

 Open retaining clips - 1 - and remove nuts - 2 - on right side of battery cover.
Fig. 16: Identifying Retaining Clips & Nuts (Left Side)

 Open retaining clips - 1 - and remove nuts - 2 - on left side of battery cover.
Fig. 17: Identifying Retaining Strap Nut

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 Remove retaining strap nuts - arrows -.

 Remove retaining straps.
Fig. 18: Identifying Battery Connection On Positive Terminal

 First, disconnect negative (-) terminal - arrow - from battery.
Fig. 19: Identifying Positive Battery Line

 Then disconnect positive (B+) terminal - arrow - from battery.
Batteries, reconnecting sequence
CAUTION:  Disconnecting and reconnecting batteries on a dual battery system

MUST be performed using the following step-by-step procedure, in
the sequence given. Failure to adhere to the following procedure will
result in the deactivation of Main Battery Switch -E74- and
subsequent damage to electrical system components.
 Battery terminals must not be greased.
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 Reconnect battery in luggage compartment.

 Reconnect battery under drivers seat.
Second battery or auxiliary battery, in luggage compartment, connecting

Fig. 21: Identifying Positive Battery Terminal

 Refit battery positive (B+) terminal - arrow - on battery positive post.

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Fig. 22: Identifying Battery Connection On Positive Terminal

 Only after the positive (B+) terminal has been secured should the negative (-) terminal clamp - arrow - be
installed.
Battery under drivers seat, reconnecting

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Fig. 24: Identifying Battery Ground Line & Battery Positive Line
 Refit battery positive (B+) terminal - 2 - on battery positive post.

 Only after the positive (B+) terminal has been secured should the negative (-) terminal clamp - 1 - be
installed.

 Install left front seat rail cover --> 72 - SEAT - FRAMES .
 Install left front seat trim --> 72 - SEAT - FRAMES .
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Work steps required after reconnecting battery
Work steps Completed?

Switch ignition on, and then off.
Check DTC memory: --> Guided Fault Finding using VAS 5051A
Steering Angle Sensor -G85-: Perform Basic Setting --> Guided Fault
Finding using VAS 5051A
Clock: Check and reset to local time.
Power windows: Completely open and close all power windows.
Perform function test of all electrical components.
BATTERY, REMOVING AND INSTALLING
Battery, removing and installing
CAUTION: When disconnecting and connecting the battery, always perform the work
procedure as described in --> Battery, disconnecting and reconnecting.
Not adhering to sequence will result in the deactivation of Main Battery
Switch -E74- and subsequent damage to electrical system components.
Battery under drivers seat, removing and installing
Battery, removing
CAUTION: When disconnecting battery, procedure must always be followed as

described in the article. Not adhering to sequence will result in the
 Disconnect battery --> Battery, disconnecting and reconnecting.
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Fig. 26: Identifying Central Gas Vent Hose

 Disconnect central gas vent hose - arrow - from top cover.
Fig. 27: Identifying Bolt & Battery Hold-Down Bracket

 Remove bolt - 1 - and battery hold-down bracket - 2 -.
Fig. 28: Identifying Bolt & Retainer Bracket

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 Remove bolt - 1 - and retainer bracket - 2 -.
Fig. 29: Identifying Battery Handles

 Fold battery handles - arrows - upward.

 Grasp battery by handles and lift from battery box.
Battery, installing
CAUTION: If battery is not secured properly, the following will result:
 Shortened battery service life due to vibration damage (explosion

hazard).
 If battery is not secured properly, the plates within the battery can be
damaged.
 Damage to battery casing caused by bracket (possible electrolyte
leakage, high subsequent costs).
 Reduced collision safety.
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Install in reverse order of removal, noting the following:
Fig. 31: Identifying Bolt & Battery Hold-Down Bracket

 Install battery hold-down bracket - 2 - and torque bolt - 1 - to value in table --> Tightening Torques:
Battery.
Fig. 32: Identifying Bolt & Retainer Bracket

 Install retainer bracket - 2 - and torque bolt - 1 - to value in table --> Tightening Torques: Battery.
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Fig. 33: Identifying Central Breather Hose

Ensure central breather hose is attached to battery - arrow - , and hose is not pinched during installation. Only
then can battery be properly vented.
 After installing, verify battery is properly seated.
CAUTION:  When connecting battery, always perform work procedure as

described in article. Not adhering to sequence will result in the
 Observe notes for threaded connections of battery terminals -->
Battery post/terminal, handling instructions.
 Reconnect battery --> Battery, disconnecting and reconnecting.
Second battery or auxiliary battery in luggage compartment, removing and installing
NOTE:  On vehicles without collapsible spare tire, an absorbent glass mat (AGM)
battery must also be installed. On vehicles with a collapsible spare tire,
there may also be a wet battery with visual indicator ("magic eye").
Battery, removing
 Disconnect batteries.
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 Disconnect central gas vent hose - arrow - from top cover.
Fig. 35: Identifying Nut & Battery Hold-DownBracket

 Remove nut - 1 - and remove battery hold-down bracket - 2 -.
Fig. 36: Identifying Battery Handles

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 Fold battery handles - arrows - upward.

 Grasp battery by handles and lift from battery box.
Battery, installing
CAUTION: If battery is not secured properly, the following will result:
 Shortened battery service life due to vibration damage (explosion

hazard).
 If battery is not secured properly, the plates within the battery can be
damaged.
 Damage to battery casing caused by bracket (possible electrolyte
leakage, high subsequent costs).
 Reduced collision safety.

 Torque battery hold-down bracket nut to value in table --> Tightening Torques: Battery.
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Ensure central venting system hose is attached to battery - arrow - and has not be clamped off during
installation. Only then can battery be properly vented.
 After installing, verify battery is properly seated.

BATTERY ISOLATOR
Battery isolator, removing and installing
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Removing:
 Disconnect batteries --> Battery, disconnecting and reconnecting.

 Remove second battery in luggage compartment --> Second battery or auxiliary battery in luggage
compartment, removing and installing.
Fig. 40: Identifying Battery Isolator

 Disconnect battery isolator connection - arrow -.
Fig. 41: Identifying Battery Isolator Nuts

 Remove nuts - arrows - and remove battery isolator upward from retainer.
 Remove nuts - arrows -.
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Fig. 42: Identifying Nuts

 Disconnect wires from battery isolator.
Installing:
 Tighten nuts and terminals to values in table --> Tightening Torques: Battery.
 Install battery in luggage compartment.

MAIN BATTERY SWITCH E74
General information
The main battery switch is used on both single and dual battery systems. The main battery switch is always
found on the battery located under the drivers seat.
NOTE:  A main battery switch that has been deactivated (battery/starter circuit
isolated) can be reset using the reset button on the switch.
CAUTION: In the event a main battery switch has been deactivated, the starter circuit
must be tested for a short circuit prior to resetting.
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Main Battery Switch E74 - assembly overview
Fig. 43: Identifying Main Battery Switch E74 Components

1 - Starter wire
2 - Threaded connection for battery cut-off switch, 20 Nm
3 - Reset button
4 - Sight glass
5 - To battery positive terminal
6 - Main battery switch
7 - Multi-pin connector
Deployment, recognizing
NOTE:  A main battery switch that has been deactivated (battery/starter circuit
isolated) can be reset using the reset button on the switch.
CAUTION: In the event a main battery switch has been deactivated, the starter circuit
must be tested for a short circuit prior to resetting.
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When activated, sight glass appears copper - 4 -. When deactivated, sight glass appears white.
Deployment, resetting
Fig. 45: Identifying Seat Slide Rail Screws

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Fig. 46: Identifying Seat Frame


Fig. 48: Identifying Retaining Tab

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 Release retaining tab - arrow - and remove cover.

 Check starter wire for short circuit according to wiring diagram. If necessary, repair short circuit.

 Press reset button - 3 - to reset main battery switch. A copper coil must be visible in viewing window - 4 -
, indicating the battery cut-off switch is reset.
 Close E-box with cover and reinstall air duct.

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Main Battery Switch E74 , removing and installing

Removing:

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Fig. 52: Identifying Retaining Tab

 Release retaining tab - arrow - and remove cover.

 If necessary, remove the lead coating on the multi-pin connector.
Fig. 53: Identifying Protective Cap Of Multi-Pin Connector And Retaining Tab
 Open protective cap - 1 - of multi-pin harness connector, disengage retaining tab - 2 - and disconnect
harness connector.
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Fig. 54: Identifying M8 Nuts

 Remove the M8 nuts - arrows - and remove battery isolation system.
Installing:
 Install and tighten starter bolts and terminal nuts to torque values in table --> Tightening Torques:
Battery.
 If necessary, replace seal on multi-pin harness connector.

TIGHTENING TORQUES: BATTERY
Tightening Torques: Battery
Threaded connection Tightening torques

Battery terminal clamp on battery M6 9 Nm
post
Additional terminal on battery M6 9 Nm
terminal clamp
Seat frame to body 45 Nm
Battery hold-down bracket to M8 23 Nm
body
Battery retainer bracket to body M6 9 Nm
Battery in luggage compartment, M6 14 Nm
battery hold-down bracket to body
Battery isolator to body M6 6 Nm
Wiring terminals to battery M8 20 Nm
isolator
Main Battery Switch to body M8 20 Nm
EXTERNAL STARTING POINT, VEHICLES THROUGH 04/05
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External starting point, vehicles through 04/05
The external starting point is in the left of the engine compartment near the left bulkhead.
External starting point, vehicles from 05/05 --> External starting point, vehicles from 05/05.
External starting point, vehicles through 04/05, assembly overview
Fig. 55: External Starting Point, Vehicles Through 04/05, Assembly Overview
1 - Collar nut
 M8
 20 Nm
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2 - External starting point housing
3 - Collar bolt
 M6
 8 Nm
4 - Hydraulic oil reservoir and external starting point bracket
5 - Socket head bolt
 M6 x 15
 8 Nm
6 - Collar nut
 M6
 10 Nm
External starting point, vehicles through 04/05, removing and installing

Removing:
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Fig. 57: Identifying Fold Up Cover

 Fold up cover - 1 -.
NOTE:  The illustrations show the external starting point on the V6 Touareg.
Vehicles with other engines have only two lines connected.
Fig. 58: Identifying Mounting Nuts

 Remove mounting nuts - arrows - and remove connected lines from connector threads.
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Fig. 59: Identifying Fold Cover Up , Mounting Nut & Connector Threads
 Fold cover up - 3 - , remove mounting nut - 2 - and remove line - 1 - from connector threads.
Fig. 60: Identifying Mounting Bolts

 Remove both mounting bolts - arrows - and remove external starting point housing upward out of
vehicle.
Fig. 61: Identifying Mounting Bolt & Hydraulic Oil Reservoir

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 Remove hydraulic oil reservoir - 1 - mounting bolt - 2 - , remove hydraulic oil reservoir - 1 - from bracket
and lays it aside with hoses connected.
Fig. 62: Identifying Bracket & Refrigerant Lines

 Unclip both refrigerant lines - 2 - from bracket - 1 -.
Fig. 63: Identifying Mounting Bolts & Starting Point Bracket

 Remove three mounting bolts - arrows - and remove hydraulic oil reservoir and external starting point
bracket - 1 - from vehicle.
Installing:
 When installing hydraulic oil reservoir, ensure it is engage correctly in reservoir and external starting
point bracket.
 Tighten all fasteners according to value specified in table --> External starting point, vehicles through
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04/05, assembly overview.

EXTERNAL STARTING POINT, VEHICLES FROM 05/05
External starting point, vehicles from 05/05
The external starting point is in the left of the engine compartment near the left bulkhead. Depending on
equipment, the form of the hydraulic oil reservoir and external starting point bracket may differ slightly from
the illustrations.
External starting point, vehicles through 04/05 --> External starting point, vehicles through 04/05.
External starting point, vehicles from 05/05, assembly overview
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Fig. 64: External Starting Point, Vehicles From 05/05, Assembly Overview
1 - Collar nut
 M8
 20 Nm
2 - Positive terminal
 SW 17
 20 Nm
3 - Multi-point socket head bolt
 M6
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 9 Nm
4 - External starting point housing
5 - Hex head collar nut
 M6
 8 Nm
6 - Hydraulic oil reservoir and external starting point bracket
7 - Torx bolt
 M6
 9 Nm
External starting point, vehicles from 05/05, removing and installing

Removing:
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Fig. 66: Identifying Positive Pole Cap & Cover

 Fold up positive pole cap - 1 - and cover - 2 -.
Fig. 67: Removing/Installing Mounting Nut, Screw & Positive Pole

 Remove mounting nut - 1 - (SW 13) and remove lines - 2 - and - 5 - from connector threads.
 Remove positive pole - 2 - (SW 17).
 Remove screw - 4 -.
 Remove external starting point housing upward from bracket while being careful of connected lines.
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Fig. 68: Identifying Retaining Tabs

 Release both retaining tabs - arrows - and remove B+ wire connecting piece - 1 - downward from
external starting point housing.
Fig. 69: Identifying Mounting Bolt & Hydraulic Oil Reservoir

 Remove mounting bolt - 1 - for hydraulic oil reservoir - 2 - , remove reservoir - 2 - from reservoir and
external starting point bracket and lay it aside with hoses connected.
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Fig. 70: Identifying Mounting Bolt, Mounting Nut, Hydraulic Oil Reservoir & External Starting Point
Bracket
 Remove mounting bolt - 1 - and mounting nut - 3 - and remove hydraulic oil reservoir and external
starting point bracket - 2 - from vehicle.
Installing:
 When installing hydraulic oil reservoir, ensure it is engage correctly in reservoir and external starting
point bracket.
 Tighten all fasteners according to value specified in table --> External starting point, vehicles from
05/05, assembly overview.

STARTER
Starter
Starter B , checking
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Fig. 71: Diagnostic Operation System VAS5051A

 Vehicle Diagnostic, Testing and Information System VAS 5051A

 Diagnostic cable VAS 5051/6A
 Connect Vehicle Diagnostic, Testing and Information System VAS 5051A --> Vehicle Diagnostic,
Testing and Information Systems.
Select operating mode "Guided Fault Finding" on Vehicle Diagnostic, Testing and Information System VAS
5051A.
After Diagnostic Trouble Code (DTC) memory of all control modules has been checked:
 Using the "Go To" button, select "Functions/Component selection" and the following menu options in
sequence:
 Body
 Electrical Equipment
 27 - Starter, power supply
 Electrical components
 Starter -B-
 Or, in Vehicle Diagnostic, Testing and Information System VAS 5051A , select operating mode "Guided
Functions".
 Body
 Starter -B-
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Starter (automatic transmission), removing and installing
Starter - 6-cyl. engine, removing and installing 3.2L fuel injection engine and 3.6L FSI engine, automatic transmission

Fig. 73: Torque Wrench V.A.G. 1332

Removing:


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 Remove noise insulation --> 50 - BODY - FRONT
Fig. 74: Identifying Open Snaps

 Open snaps - arrows - and remove starter solenoid heat shield mat.
Fig. 75: Identifying Protective Caps

 Pry off protective caps for mounting nuts - arrows -.
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Fig. 76: Identifying Positive Solenoid Terminal Nut

 Remove nut at solenoid positive (B+) terminal - arrow -.
Fig. 77: Identifying Solenoid Terminal Nut

 Remove nut at solenoid Terminal 50 - arrow -.
CAUTION: Screw connections on magnetic switch can twist.
The solenoid switch can be damaged.
When removing and installing nuts at positive terminal and terminal 50,
counterhold the threaded connection at the solenoid switch using an
open-end wrench.
Fig. 78: Identifying Lower Starter Bolt

 Remove lower starter bolt M12x60 - arrow - on engine side.
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Fig. 79: Identifying Nuts and Cable Retainer

 Remove bolt - 2 - for cable retainer and set aside.

 Remove nuts - 1 -.
Fig. 80: Identifying Bolt & Exhaust System Bracket

 Remove bolt - 1 - from exhaust system bracket - 2 - from engine side and remove bracket.
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Fig. 81: Identifying Coolant Pipe Bolt

 Remove bolt for coolant pipe - arrow - at engine sump.
Fig. 82: Identifying Start Upper Bolt

 Remove the upper bolt for the starter - arrow - on the transmission side.
 Remove starter.
Installing
Starter.
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Starter - 8 cyl. 4.2 L fuel injection engine (MPI), automatic transmission, removing and installing
Fig. 83: Identifying Special Tools - Starter - 8 Cyl. 4.2 L Fuel Injection Engine (MPI), Automatic
Transmission, Removing And Installing

 Shop crane VAS 6100
 Lifting tackle 3033
Removing:
 Remove engine -->

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 10 - ENGINE - ASSEMBLY for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION

IGNITION, ENGINE CODES: BAA, BMX
IGNITION, ENGINE CODES: BHL, BHK
 10 - ENGINE - ASSEMBLY for 4.2 LITER V8 4V ENGINE MECHANICAL, FUEL
INJECTION IGNITION, ENGINE CODE(S): BAR
INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX
 10 - ENGINE - ASSEMBLY for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL, FUEL
INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF
.
 Remove exhaust manifold -->
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2L V6 4V ENGINE MECHANICAL,
FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.6L V6 4V ENGINE MECHANICAL,
FUEL INJECTION IGNITION, ENGINE CODES: BHL, BHK
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE
MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BAR
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE
MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX
 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 5.0 LITER V10 2V TDI PD ENGINE
MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF
.
Fig. 84: Identifying Bolt, Cable Harness & Cable Retainer

 Remove bolt - 1 -.
 Unclip cable harness - 2 - and remove cable retainer - 3 - from mounting.
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Fig. 85: Identifying Engine Mount Nut

 Remove nut - arrow - from engine mount.
Fig. 86: Identifying Screws

Fig. 87: View of Hook and Lifting Tackle

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 Hook the lifting tackle 3033 on right cylinder head (toothed belt side) and on left cylinder head (flywheel
side).
 Hook the lifting tackle 3033 into the shop crane VAS 6100.
 Lift the engine with the shop crane VAS 6100.
 Remove engine mount.
 Remove three bolts for engine mount bracket at engine block.

 Remove engine bracket.
Fig. 88: Identifying Protective Caps

 Remove protective caps - arrows -.
Fig. 89: Identifying Positive Terminal & Terminal 50 Nuts

 Remove nut at terminal 50 - 1 - and nut at positive (B+) terminal - 2 - and remove cables from solenoid.

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open-end wrench.
 Set the wires aside.

 Remove the lower bolt for the starter - arrow - on the engine side.
Fig. 91: Identifying Upper Starter Bolt

 Remove the upper bolt for the starter - arrow - on the transmission side.
 Remove starter.
Installing:
Starter.
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Starter - 8 cyl. fuel injection engine (FSI), automatic transmission, removing and installing
Fig. 92: Identifying Special Tools - Starter - 8 Cyl. Fuel Injection Engine (FSI), Automatic Transmission,
Removing And Installing

 Lifting tackle 2024 A
Removing:
 Remove the engine -->

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.


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Fig. 95: Identifying Lifting Tackle & Shop Crane

 Engage Lifting Tackle 2024 A in lifting eyes on cylinder heads.

 Hook the lifting tackle 2024 A into the shop crane VAS 6100.
 Remove engine mount.
 Remove three bolts for engine mount bracket at engine block.

 Move engine bracket slightly to side.
NOTE:  Engine bracket must not be removed completely. Ground lines remain
connected.
 Remove upper starter bolt - arrow - on transmission side.
Fig. 96: Identifying Heat Shield & Upper Starter Bolt

 Remove heat shield - 2 - from wiring retainer.
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 Remove the lower bolt for the starter - arrow - on the engine side.
 Remove starter from transmission housing, being careful of wires.
 Disconnect electrical connection - 1 -.
Fig. 98: Identifying Protective Cap & Electrical Connector

 Remove protective cap - 2 - and nut beneath.

 Remove starter.
Installing:
Starter.
Starter - 10 cyl. 5.0L TDI engine, automatic transmission, removing and installing
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Fig. 99: Identifying Special Tools - Starter - 10 Cyl. 5.0L TDI Engine, Automatic Transmission,
Removing And Installing

 Lifting tackle 3033
 Transportation plates T10126

 Transportation plates T10126/1
Removing:
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.
 Remove right turbocharger --> 21 - TURBOCHARGER, G-CHARGER .
Fig. 100: Identifying Open Snaps

 Open snaps - arrows - and remove starter solenoid heat shield mat.

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Fig. 102: Identifying Transport Strap & Bolt (Right Cylinder Head)
 Bolt transport strap T10126 - 1 - with a bolt M8x40 - 2 - to right cylinder head at rear.
CAUTION: When bolting on, transport strap pin must engage into bore of holder
attached on engine side.
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Fig. 103: Identifying Transport Strap & Bolt (Left Cylinder Head)
 Bolt transport strap T10126/1 - 1 - with a bolt M8x40 - 2 - to left cylinder head at front.
CAUTION: When bolting on, transport strap pin must engage into bore of holder
attached on engine side.
 Hook the lifting tackle 3033 into the shop crane VAS 6100.
 Hook transport straps T10126 and T10126/1 onto lifting tackle 3033.
Fig. 104: Identifying Right Engine Support Bolts

 Remove 4 bolts M10x95 - arrows - from right engine support and remove engine support.
Fig. 105: Identifying Coolant Pipe Bolt

 Remove bolt for coolant pipe - arrow - at engine block.
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Fig. 106: Identifying Transmission Coolant Pipe Bolt

 Remove bolt for coolant pipes - arrow - at transmission.
Fig. 107: Identifying Positive Terminal Protective Cap

 Pry off cap from nut at positive (B+) terminal - arrow -.
Fig. 108: Identifying Positive Terminal Solenoid Nut

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 Remove nut at solenoid positive (B+) terminal - arrow -.
Fig. 109: Identifying Terminal Solenoid Nut

 Remove nut at solenoid Terminal 50 - arrow -.
open-end wrench.
Fig. 110: Identifying Cable Retainer Bolt

 Remove bolt for cable retainer - arrow - and set cables aside.
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Fig. 111: Identifying Lower Starter Bold

 Remove lower starter bolt M12x165 - arrow - on engine side.
Fig. 112: Identifying Upper Starter Bolt

 Remove upper starter bolt M12x165 - arrow - on transmission side.

 Remove starter.
Installing:
Starter.
TIGHTENING TORQUES: STARTER
6-cyl. fuel injection engine, 3.2L and 3.6L FSI engine

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Starter bolt M12x60 75 Nm

Wire terminal 50 to starter 8 Nm
solenoid switch
Positive wire to solenoid switch 15 Nm
8-cyl. 4.2L fuel injection (FSI) engine

Starter bolt M10 x 205 45 Nm
Starter bolt M12 x 80 65 Nm
solenoid switch
Engine bracket to cylinder block 60 Nm
Engine bracket to engine mount 75 Nm
8-cyl. 4.2L fuel injection (MPI) engine

Starter bolt 40 Nm
Wire terminal 50 to starter solenoid switch 8 Nm
Engine bracket to cylinder block 60 Nm
10-cyl. TDI engine 5.0L

Starter bolts M12x165 65 Nm
solenoid switch
Engine bracket to cylinder block M10x95 60 Nm
GENERATOR
Generator
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NOTE:  Checking generator: --> Electrical Wiring Diagrams, Troubleshooting and

Component Locations
Generator features
Based on engine variations, different types of generators were installed.
In vehicles with 6-cylinder gasoline generator has the following characteristics:
 The generator is driven by a ribbed belt.

 The voltage regulator cannot be replaced separately. If a repair is necessary, the entire generator must be
replaced.
 The generator is cooled by the engine coolant circuit. As of model year 2005.
For vehicles with 8 cyl. fuel injection engine, the generator has the following characteristics:
 The generator is driven by a ribbed belt.

replaced.
 The generator is cooled by the engine coolant circuit.
In vehicles with 10-cyl. TDI engines, the generator has the following features:
 Generator shaft is driven by a clutch bolted to one-way clutch on generator side. On the engine side, a
hub grabs in the clutch. This hub is connected by a shaft to a gear in the engine control.
 The generator is cooled by the engine coolant circuit.
replaced.
Generator positive (B+) connection, securing
CAUTION: If B+ terminal nut is not torqued as specified, the following may result:
 Battery will not be completely charged.

 The complete electrical/electronics systems may fail (disabled
vehicle).
 Fire hazard due to arcing.
 Damage to electronic components and control modules caused by
excessive voltage.
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Fig. 113: Terminal B+ Nut

 The tightening torque for the B+ wire mounting nut - arrow - can be found in the respective generator
assembly overview.
Ribbed belt, checking
 Turn over engine at vibration damper/belt pulley using a socket wrench.

 Check the ribbed belt for:
 Cracks in the underside (surface cracks, fragmenting, cross-section breaks)

 Layer separation (outer layer, tension cords)
 Wear-through on the underside
 Fraying of tension cords
 Edge wear (material wear, frayed edges, hardened edges -glazed edges-, surface cracks)
 Oil and grease traces
CAUTION: If defects are discovered, the ribbed belt must be replaced immediately.
Thereby, failures and malfunctions can be prevented.
Generator (GEN) C , checking
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Fig. 115: Diagnostic Cable - VAS 5051/6A

 Connect Vehicle Diagnostic, Testing and Information System VAS 5051A --> Vehicle Diagnostic,
Select operating mode "Guided Fault Finding" on Vehicle Diagnostic, Testing and Information System VAS
5051A.
After Diagnostic Trouble Code (DTC) memory of all control modules has been checked:
sequence:
 Body
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 Generator (GEN) -C-
 Or, in Vehicle Diagnostic, Testing and Information System VAS 5051A , select operating mode "Guided
Functions".
 Body
 Generator (GEN) -C-
Generator, air-cooled, 6 cyl. 3.2L fuel injection engine
Vehicles with engine codes AZZ, BAA, BKJ (162 kW).
Vehicles with engine codes BMV, BMX, BRJ (177 kW).
Assembly overview
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Fig. 116: Exploded View Of Generator Components

1 - Socket head bolt with washer
 M8 x 30 mm
 20 Nm
2 - Tension roller
 M8 x 40 mm
 20 Nm
4 - Fitted bolt with washer

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 M8 x 25 mm
 20 Nm
5 - Socket head bolts with washer
 M8 x 40 mm
 20 Nm
6 - Fitted bolt with washer
 M8 x 25 mm
 20 Nm
7 - Bracket
8 - Idler pulley
9 - Fitted bolt with hex head
 Component of relay pulley item 8, cannot be replaced separately

 M10 x 50 mm
 40 Nm
10 - Cover
11 - Generator
 B+ wire fastener to generator, 15 Nm

 Neither voltage regulator nor carbon brushes can be replaced individually; if a repair is required, entire
generator must be replaced.
 Generator, removing and installing
 Generator ribbed belt pulley, removing and installing
12 - Ribbed belt
 Ribbed belt, checking --> Ribbed belt, checking

 Ribbed belt routing
13 - Collar bolts
 M8 x 90 mm
 20 Nm
Generator, 6-cyl. 3.2L air-cooled fuel injection engine, removing and installing
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 Bolt M8 x 50 (commercially available - pressure bolt for ribbed belt tensioner)
Removing:

Fig. 118: Identifying DF-Lead Connector & Protective Cap

 Separate the connector for the DF-lead - 1 - and remove the protective cap - 2 -.
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 Remove the B+ lead - arrow - from the generator.
CAUTION: Before removing ribbed belt, mark the top side and direction of travel.
When installing, pay attention to correct running direction and installation
position. If the belt is installed in the opposite running direction or is
positioned incorrectly, the belt will fail!
 Remove air guides above cooler.
Fig. 120: Identifying Pressure Bolt

 Install pressure bolt M8x50 - arrow - in tensioner threaded bore until ribbed belt can be removed.
CAUTION: Tensioner housing may be damaged.
If hex bolt is threaded too far into tensioner housing, the housing may be
damaged.
Only screw the bolt in so far until the ribbed belt can be removed.
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Fig. 121: Identifying Tensioner Bolts

 Remove bolts for tensioner - arrows -.

 Remove the ribbed belt together with the tensioner.
Fig. 122: Identifying Generator Bolts

 Remove generator mounting bolts M8 x 90 - arrows -.
Installing:
CAUTION:  When installing an already used ribbed belt, note direction of travel
marked when it was removed!
 Before installing the ribbed belt, make sure all drive accessories
(generator, air conditioner compressor, power steering pump) are
secured in place.
 When installing the ribbed belt, make sure it is properly seated in the
belt pulley!
 Make sure that the pressure bolt M8x50 has been removed from
tensioner.
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Fig. 123: Driving Threaded Sleeves From Generator Housing

 Drive threaded sleeves - A - out of generator housing approx. 4 mm in direction of arrow.

 Tighten threaded connections to torques given in assembly overview.


 Start the engine and verify that the belt is running properly.
Ribbed belt routing, 6-cyl. 3.2L fuel injection engine
Fig. 124: Identifying Ribbed Belt Components

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1 - Belt pulley - generator
2 - Idler pulley
3 - Idler pulley
4 - Belt pulley - coolant pump
5 - Belt pulley - power steering pump
6 - Belt pulley - air conditioner compressor
7 - Tension roller
8 - Belt pulley - crankshaft
Generator, coolant-cooled 6-cyl. 3.2L fuel injection engine and 3.6L FSI engine
Vehicles with engine codes BHK, BHL (206 kW).
Assembly overview
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Fig. 125: Generator, Coolant-Cooled 6-Cyl. 3.2L Fuel Injection Engine And 3.6L FSI Engine Assembly
overview
1 - Tension roller
2 - Socket head bolts
 M8 x 30 mm
 20 Nm
3 - Fitting bolts
 M8 x 28 mm
 20 Nm
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4 - Bracket
5 - Coolant hose
 Connection diagram for coolant hoses -->

 19 - ENGINE - COOLING SYSTEM for 3.2L V6 4V ENGINE MECHANICAL, FUEL
INJECTION IGNITION, ENGINE CODES: BAA, BMX
INJECTION IGNITION, ENGINE CODES: BHL, BHK
 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 4V ENGINE MECHANICAL, FUEL
 19 - ENGINE - COOLING SYSTEM for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL,
FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF
.
6 - Clamp
7 - Torx flat head bolt
 M6 x 16 mm
 9 Nm
8 - Connecting piece
9 - O-Ring
 Always replace
10 - Generator

 Neither the voltage regulator nor the carbon brushes can be replaced individually; if a repair is required,
the entire generator must be replaced.
11 - Ribbed belt
 Checking ribbed belt --> Ribbed belt, checking.

12 - Collar bolts
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 M8 x 90 mm
 20 Nm
13 - Idler pulley
14 - Bolt
 M10 x 45 mm
 20 Nm
15 - Cover
 M8 x 30 mm
 20 Nm
Generator, coolant-cooled, 6 cyl. 3.2L fuel injection engine and 3.6L FSI engine

 Torque wrench V.A.G 1331
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Fig. 127: Hose Clamps 3093

 Hose clamps up to 40 mm dia. VAS 3093

 Bolt M8 x 50 (commercially available - pressure bolt for ribbed belt tensioner)
Removing:

described in --> Battery, disconnecting and reconnecting. If the sequence
is not followed, the pyrotechnic battery isolation system switch may
trigger, which may damage electrical components in the vehicle.
Fig. 128: Identifying Protective Cap

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 Remove protective cap - arrow - of B+ wire.
Fig. 129: Identifying B + Wire Harness & DF Wire

 Unscrew B+ wire - 1 - and disconnect harness connector of DF wire - 2 -.
Fig. 130: Identifying Coolant Hose Clamps

 Clamp off coolant hoses using hose clamps up to Ø 40 mm VAS 3093.
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Fig. 131: Identifying Protective Cap

 Remove bolt - arrow -.

 Pull coolant pipes off generator.
NOTE:  The coolant hoses may remain connected to the coolant pipes.
Fig. 132: Identifying Pressure Bolt

 Install pressure bolt M8x50 - arrow - in tensioner threaded bore until ribbed belt can be removed.
CAUTION: Only screw the bolt in so far until the ribbed belt can be removed.
Otherwise, tensioner housing can be damaged.
Fig. 133: Identifying Tensioner Bolts

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 Remove bolts for tensioner - arrows -.

 Remove the ribbed belt together with the tensioner.
Fig. 134: Identifying Generator Mounting Bolts

 Remove generator mounting bolts M8 x 90 - arrows -.

 Remove generator from bracket.
Installing:
secured in place.
belt pulley!
 Make sure that the pressure bolt M8x50 has been unscrewed from
tensioner.

 Remove pressure bolt M80 x 50 from tensioner.
 Fill with coolant -->
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.
CAUTION:  When connecting the battery, always perform the work procedure as
described in --> Battery, disconnecting and reconnecting. If the
sequence is not followed, the pyrotechnic battery isolation system
switch may trigger, which may damage electrical components in the
vehicle.
 Observe notes for threaded connections on battery poles --> Battery
post/terminal, handling instructions.

 Start the engine and verify that the belt is running properly.
Ribbed belt path - 3.2 L 6-cyl. fuel injection engine and 3.6L FSI engine
Fig. 135: Ribbed Belt Path - 3.2 L 6-Cyl. Fuel Injection Engine And 3.6L FSI Engine
2 - Idler pulley
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5 - Ribbed belt - generator, idler pulley, air conditioner compressor, power steering pump, crankshaft, coolant
pump and tensioner
7 - Belt pulley - coolant pump
8 - Tension roller
Generator, 8-cyl. 4.2L fuel injection (MPI) engine
Vehicles with engine code AXQ (228 kW).
Assembly overview
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Fig. 136: Generator, 8-Cyl. 4.2L Fuel Injection (MPI) Engine Assembly overview
1 - Angle bracket
 M6 x 25 mm
 9 Nm
3 - Coolant pipe
4 - Clamp
5 - Coolant hose
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 Connection diagram for coolant hoses -->

6 - O-Ring
 Replace
7 - Generator

 Generator ribbed belt pulley, removing and installing
8 - Ribbed belt
 Ribbed belt, checking --> Ribbed belt, checking

 M8 x 90 mm
 22 Nm
Generator, 8-cyl. 4.2L fuel injection (MPI) engine, removing and installing
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Fig. 138: Mandrel T10060 A

 Mandrel T10060 A
Removing:
 Remove engine -->

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Fig. 139: Relieving Tension On Ribbed Belt By Pivoting Tensioning Element Using A Box-End Wrench.
 Relieve tension on the ribbed belt by pivoting the tensioning element using a box-end wrench.
 Lock tensioner using mandrel T10060 A.
Fig. 140: Identifying DF-Wire Harness Connector

 Disconnect harness connector of DF-wire.
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Fig. 141: Identifying Protective Cover

 Pull off the protective cover - arrow -.
Fig. 142: Identifying B+ Lead

Fig. 143: Identifying Coolant Lines, Bracket & Bolt

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 Remove the bolt - 1 - and remove the bracket - 2 - for the coolant lines from the generator.
 Remove coolant lines - 3 - from generator.

 Remove the mounting bolts M8x90 for the generator - arrows -.
Installing:
secured in place.
belt pulley!

 Replace the coolant line gaskets.
Ribbed belt routing, 8-cyl. 4.2L fuel injection (MPI) engine
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Fig. 145: Ribbed Belt Routing, 8-Cyl. 4.2L Fuel Injection (MPI) Engine
2 - Tension roller
4 - Idler pulley
7 - Ribbed belt - generator, idler pulley, air conditioner compressor, power steering pump, crankshaft, coolant
pump and tensioner
Generator, 8-cyl. 4.2L fuel injection engine (FSI)
Vehicles with engine code BAR (257 kW).
Assembly overview
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Fig. 146: Generator, 8-Cyl. 4.2L Fuel Injection Engine (FSI) Assembly overview
1 - Screw
 22 Nm
2 - Tensioner for ribbed belt
3 - Ribbed belt
 Checking ribbed belt --> Ribbed belt, checking.

4 - Cover
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5 - Screw
 M8 x 90 mm
 22 Nm
6 - Generator

7 - Screw
 M8 - 22 Nm
 M10 - 46 Nm
8 - Bushing
 Qty. 2
9 - Bracket
10 - Screw
 9 Nm
11 - Mounting bracket
 For idler pulley
12 - Ribbed belt idler pulley
13 - Screw
 22 Nm
15 - Screw
 22 Nm +45° (1 /8 additional turns)

 Replace
16 - Bushing
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 Qty. 2
17 - Bracket
 For ribbed belt tensioner
18 - Screw
 9 Nm
Generator, 8-cyl. 4.2L fuel injection engine (FSI), removing and installing

Removing:

.
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 Remove ribbed belt -->

 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 3.2L V6 4V ENGINE
MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BAA, BMX
 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 3.6L V6 4V ENGINE
MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODES: BHL, BHK
 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 4.2 LITER V8 4V ENGINE
MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BAR
 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 4.2 LITER V8 5V ENGINE
MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX
 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 5.0 LITER V10 2V TDI PD
ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BKW, BWF
Fig. 148: Identifying DF-Wire Harness Connector

 Disconnect harness connector of DF-wire.
Fig. 149: Identifying Protective Cover

 Pull off the protective cover - arrow -.
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Fig. 150: Identifying B+ Lead

Fig. 151: Identifying Coolant Lines, Bracket & Bolt


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 Remove the mounting bolts M8x90 for the generator - arrows -.
Installing:
secured in place.
belt pulley!
 Install and torque starter bolts and terminal nuts to values in table.
 Replace the coolant line gaskets.
Ribbed belt routing, 8-cyl. 4.2L fuel injection engine (FSI)
Fig. 153: Ribbed Belt Routing, 8-Cyl. 4.2L Fuel Injection Engine (FSI)
2 - Ribbed belt
3 - Idler pulley
5 - Tension roller
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Generator, 10-cyl. 5.0L TDI engine
Vehicles with engine codes AYH, BKW, BLE and BWF (230 kW).
NOTE:  Only generators by Hitachi are delivered as replacement parts. The Delphi
generator is no longer produced. Converting generator, Delphi to Hitachi.
 On generators with hard rubber disc clutch, this should generally be
replaced with torsion-elastic clutch.
Generator with hard-rubber disc clutch, assembly overview
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Fig. 154: Generator With Hard-Rubber Disc Clutch, Assembly Overview

 M6 x 20 mm
 8 Nm
2 - Coolant pipe/T-piece
 Converting generator, Delphi to Hitachi
3 - O-Ring
 Always replace
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4 - Angle bracket
5 - Bolts
 M8 x 35 mm
 20 Nm
6 - Generator

 One-way clutch at generator, removing and installing
7 - Hard-rubber disc clutch
 Converting to torsion-elastic clutch.
8 - Hex bolts with socket head and point
9 - Drive hub
10 - Bolt
11 - Alignment bushings
NOTE:  Check if alignment bushings are equipped and securely seated. If

alignment bushings are loose, coat them with commercially available
grease before installing.
12 - O-Ring
 Always replace
13 - Coolant pipe
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Generator, 10 cyl. 5.0L TDI engine with hard rubber disc clutch (vehicles with engine code AYH, BKW), removing and installing

Removing:

described in --> Battery, disconnecting and reconnecting. Not adhering to
sequence will result in the deactivation of Main Battery Switch -E74- and
Before removing generator, perform the following work procedures:
 Drain coolant -->

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.
 Remove fuel filter module -->
 20 - FUEL SUPPLY for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION,
ENGINE CODES: BAA, BMX
ENGINE CODES: BHL, BHK
 20 - FUEL SUPPLY for 4.2 LITER V8 4V ENGINE MECHANICAL, FUEL INJECTION
IGNITION, ENGINE CODE(S): BAR
IGNITION, ENGINE CODE(S): AXQ, BHX
 20 - FUEL SUPPLY for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL, FUEL
.
 Remove upper section of oil filter housing -->
 17 - ENGINE - LUBRICATION for 3.2L V6 4V ENGINE MECHANICAL, FUEL INJECTION
 17 - ENGINE - LUBRICATION for 4.2 LITER V8 4V ENGINE MECHANICAL, FUEL
 17 - ENGINE - LUBRICATION for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL,
.
 Remove intake manifolds --> 23 - DIESEL FUEL INJECTION .
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Fig. 156: Identifying Coolant Line, Bracket & Bolt


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Fig. 159: Removing/Installing Bolt & Bracket

 Remove the bolt - 1 - and remove the bracket - 2 - for the B+ lead from the generator.

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 Remove the mounting bolts - arrows - for the generator.
Fig. 161: Identifying Clutch Bolts

 Remove the bolts - arrows - for the clutch.
NOTE:  There are a total of 3 bolts which, by turning the generator shaft, must be
brought into the correct position to be removed.
 Lift out generator with clutch.
Installing:
 Convert generator to torsion-elastic clutch.
Fig. 162: Check That Alignment Bushings Are Equipped & Securely Seated
NOTE:  Check if alignment bushings are equipped and securely seated - arrows -.
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If alignment bushings are loose, coat them with commercially available

 Tighten threaded connections to torques given in corresponding assembly overview or.

.

Generator with torsion-elastic clutch, assembly overview
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Fig. 163: Generator With Torsion-Elastic Clutch, Assembly Overview

 M6 x 20 mm
 8 Nm
2 - Coolant pipe/T-piece
3 - O-Ring
 Always replace
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4 - Angle bracket
5 - Bolts
 M8 x 35 mm
 20 Nm
6 - Generator

 Generator, removing and installing.
 One-way clutch at generator, removing and installing
7 - Torsion-elastic clutch
 Always replace
8 - Drive gear
9 - Bolt
 M10 x 1 x 30 mm
 50 Nm + 90°
NOTE:  Check if alignment bushings are equipped and securely seated. If

alignment bushings are loose, coat them with commercially available
11 - O-Ring
 Always replace
12 - Coolant pipe
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Generator, 10 cyl. 5.0L TDI engine with torsion-elastic clutch (vehicles with engine code AYH, BKW), removing and installing

Removing:


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.
 Remove fuel filter module -->
ENGINE CODES: BAA, BMX
ENGINE CODES: BHL, BHK
IGNITION, ENGINE CODE(S): BAR
IGNITION, ENGINE CODE(S): AXQ, BHX
 20 - FUEL SUPPLY for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL, FUEL
.
 Remove upper section of oil filter housing -->
 17 - ENGINE - LUBRICATION for 5.0 LITER V10 2V TDI PD ENGINE MECHANICAL,
.
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Fig. 170: Removing/Installing Generator

 Remove the generator. When doing this, the torsion-elastic clutch - 1 - remains on the drive gear.
Installing:

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Generator, 10 cyl. 5.0L TDI engine (vehicles with engine code BLE, BWF), removing and installing

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Removing:


.
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Fig. 173: Exploded View Of Coolant Pipe Bolt

NOTE:  To remove EGR valve, remove coolant pipe bolt - arrow -.
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Fig. 179: Removing/Installing Generator

 Remove the generator. When doing this, the torsion-elastic clutch - 1 - remains on the drive gear.
Installing:

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.

Converting generator, Delphi to Hitachi
Only generators by Hitachi are delivered as replacement parts. The Delphi generator is no longer produced.
Fig. 181: Identifying Generator Components

The following components should be replaced when converting:
1 - Generator, Hitachi 07Z 903 021 E
2 - Coolant pipe/angled piece 07Z 121 132 H
3 - B+ wire 07Z 971 349 B

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4 - Coolant pipe/T-piece 07Z 121 132 L
 Remove generator --> Generator, 10-cyl. 5.0L TDI engine.

 Replace coolant pipes and.
 Replace B+ wire.
 Install generator --> Generator, 10-cyl. 5.0L TDI engine.
Generator ribbed belt pulley, removing and installing
Vehicles with 6-cyl. fuel injection engine

Fig. 183: Identifying Multi-Point Socket 3400

 Multi-point adapter VAS 3400
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Removing:
 Remove generator.
 Tighten the generator in a vise at the attachment points.
 Remove the protective cap from the free-wheeling belt pulley.
Fig. 184: Inserting Multi-Point Adapter 3400 Into Free-Wheeling Belt Pulley & Multi-Point Socket Insert
M10 Into Generator Shaft
 Insert the multi-point adapter 3400 - 1 - with a box-end wrench into the free-wheeling belt pulley - 2 - of
the generator. Then, insert a multi-point socket insert M10 - 3 - into the generator shaft.
 Loosen the threaded connection by rotating clockwise, while counter holding with the box-end wrench.
 Hold the free-wheeling belt pulley firmly by hand and rotate it on the generator drive shaft until the free-
wheeling belt pulley can be removed.
Installing:
 First screw overrunning clutch pulley on generator driveshaft by hand until limit stop.
Torque wrench must be reassembled for installing overrunning clutch pulley as follows:
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Fig. 185: Torque Wrench Socket Drive Grip

 Release the insert - 1 - and pull it from the handle - 2 -.

 Rotate the handle - 2 - of the torque wrench 180 degrees and re-insert the bit.
 Set the rotation direction of the torque wrench bit to "left."
Fig. 186: Counterholding Multi-Point Adapter 3400 And Tightening Overrunning Clutch Pulley By
Turning Generator Drive Shaft Toward Left
 Counterhold multi-point adapter 3400 - 1 - using open end wrench 17 mm and tighten overrunning clutch
pulley by turning generator drive shaft toward left using torque wrench - 2 -. The tightening torque is 80
Nm.
 Clip the protective cap onto the free-wheeling belt pulley.
Vehicles with 8-cyl. fuel injection engine
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 Torque wrench V.A.G 1332
Fig. 188: Socket VAS 3310

 Socket VAS 3310
Removing:
 Remove generator.
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Fig. 189: Loosen/Tighten Nut At Pulley With Wrench And Adapter 3310
 Use socket insert VAS 3310 to remove mounting nut of overrunning clutch pulley from generator shaft.
Installing:
 Tighten ribbed belt pulley to generator shaft threaded connection to 65 Nm.
Freewheeling clutch at generator, removing and installing
Vehicles with 10-cyl. TDI engine

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Fig. 191: Identifying Multi-Point Socket 3400

 Multi-point adapter VAS 3400
Removing:
 Remove generator or.

Fig. 192: Identifying Special Tool Multi Point Adapter VAS 3400
Insert multi-point adapter VAS 3400 - 1 - in generator freewheel pulley - 2 - using open end wrench 17 mm.
Then, insert a multi-point socket insert M10 - 3 - into the generator shaft.
 Loosen the threaded connection by rotating clockwise, while counter holding with the box-end wrench.
 Hold free in place by hand and turn at generator drive shaft until the free can be removed.
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Installing:
 First screw free on generator driveshaft by hand until limit stop.
Torque wrench must be re-assembled for installing free as follows:
Fig. 193: Torque Wrench Socket Drive Grip

 Release the insert - 1 - and pull it from the handle - 2 -.

 Rotate the handle - 2 - of the torque wrench 180 degrees and re-insert the bit.
 Set the rotation direction of the torque wrench bit to "left."
Fig. 194: Identifying Multi-Point Adapter VAS 3400 & Torque Wrench
 Counterhold multi-point adapter VAS 3400 - 1 - using open end wrench 17 mm and tighten free by
turning generator drive shaft toward left using torque wrench - 2 -. The tightening torque is 80 Nm.
 Tighten one-way clutch to generator shaft threaded connection to 80 Nm.
CRUISE CONTROL SYSTEM (CCS)

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Cruise Control System (CCS)
Cruise Control System (CCS) functions are controlled by the Engine Control Module (ECM).
Cruise control is operated with two button blocks in the multi-function steering wheel or, on vehicles without a
multi-function steering wheel, with front rocker switch in windshield washer lever.
 Perform assembly work at multi-function steering wheel --> 91 RADIO, TELEPHONE,

NAVIGATION, TRIP COMPUTER .
 Perform assembly work on windshield wiper lever --> Steering column switch, removing and installing
 Cruise Control System (CCS) can be activated/deactivated --> Cruise Control System (CCS),
activating and deactivating.
DTC recognition and display:
DTCs in conjunction with Cruise Control System are transmitted via Engine Control Module (ECM) and via
Steering Column Electronic Systems Control Module J527.
Use Vehicle Diagnosis, Testing and Information System VAS 5051A in operating mode "Guided Fault Finding"
for troubleshooting.
Cruise Control System (CCS), activating and deactivating
ADAPTIVE CRUISE CONTROL (ACC)
General information
NOTE:  Additional information:
--> Self Study Program
Owners Manual
--> Electrical Wiring Diagrams, Troubleshooting and Component Locations
General Description:
Adaptive Cruise Control (ACC) is a cruise control system with distance regulation that influences driving
behavior with both active acceleration and deceleration.
Using Adaptive Cruise Control, any speed between 30 km/h and 200 km/h can be maintained. In addition, ACC
maintains a pre-set time distance to the vehicle ahead.
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With active brake intervention, the vehicle can be braked to a stop if the situation requires. System-specified
thresholds are set and driver intervention is prompted with optical and acoustic warnings when necessary.
The driver assistance system is activated using the front button in the turn signal level and a selection display in
the instrument cluster display. ACC is operated using the multi-function steering wheel buttons or, on vehicles
without multi-function steering wheel, using the front rocker switch in the windshield wiper lever. While
driving, important information is shown in the instrument cluster display.
Distance Regulation Control Module J428 is equipped with On Board Diagnostics (OBD) which assists
troubleshooting.
For fault finding, use one of the systems described in the "Vehicle Diagnosis, Testing and Information System"
chapter in "Guided Fault Finding" function.
When first commissioning or replacing Distance Regulation Control Module J428 , initialize ADR -->
Initializing Automatic Distance Regulation (ADR).
Adaptive Cruise Control (ACC) components:
 Distance Regulation Control Module J428

 Adaptive Cruise Control Button E357 in turn signal switch
 Depending on equipment, for adjusting ACC, the multi-function steering wheel buttons or
 The front rocker switch on the windshield wiper lever
Assembly overview
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Fig. 195: Exploded View Of Adaptive Cruise Control Button E357 & Distance Regulation Control
Module J428
1 - Adaptive Cruise Control Button E357
The Adaptive Cruise Control Button E357 is integrated in the turn signal switch on the steering column.
Turn signal switch on steering column, removing and installing --> Steering column switch, removing and
installing.
2 - Distance Regulation Control Module J428
Distance Regulation Control Module J428 must not be disassembled further and contains the following
components:
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 Adaptive Cruise Control Sensor G550
 Distance Regulation Sensor Heater Z47
Distance Regulation Control Module J428 , removing and installing --> Distance Regulation Control Module
J428 , removing and installing.
Adaptive Cruise Control Button E357 , removing and installing
The Adaptive Cruise Control Button E357 is integrated in the turn signal switch on the steering column.
Turn signal switch on steering column, removing and installing --> Steering column switch, removing and
installing.
Distance Regulation Control Module J428 , removing and installing
Distance Regulation Control Module J428 is mounted on front of vehicle, behind VW-logo in the radiator
protective grille.
components:

Removing:
 Switch off ignition, switch off all electrical consumers and remove ignition key.
 Remove radiator grille --> 66 - EXTERIOR EQUIPMENT .
Fig. 196: Distance Regulation Control Module J428 And Retainers

 Unclip Distance Regulation Control Module J428 - 1 - from the three mounts - 2 -.
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 Swivel Distance Regulation Control Module J428 - 1 - forward, paying attention to lengths of connected
wires.
Fig. 197: Distance Regulation Control Module J428 And Electrical Connection
 Disengage and disconnect harness connector - 2 - and remove Distance Regulation Control Module J428
from vehicle.
Installing:
Adaptive Cruise Control Sensor G550 in Distance Regulation Control Module J428 is to be calibrated after:
 Every removal and installation of Adaptive Cruise Control Sensor G550 ,

 Every removal and installation, and replacement of assembly carrier,
 If there is a suspicion of forceful impact on these two parts, an accident during driving or similar.
Distance Regulation Sensor G550 , calibrating --> Adaptive Cruise Control Sensor G550 , calibrating.
 When first commissioning or replacing Distance Regulation Control Module J428 , initialize ADR -->
Initializing Automatic Distance Regulation (ADR).
Adaptive Cruise Control Sensor G550 , calibrating
Adaptive Cruise Control Sensor G550 in Distance Regulation Control Module J428 is to be calibrated after:
 Every removal and installation of Adaptive Cruise Control Sensor G550 ,

 Every removal and installation, and replacement of assembly carrier,
 Considering physical forces such as collision damage or similar,
 If toe and/or camber were adjusting during a vehicle alignment.
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Adaptive Cruise Control Sensor G550 , calibrating: --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT
Initializing Automatic Distance Regulation (ADR)
NOTE:  Initialization is required only when first commissioning or replacing

Distance Regulation Control Module J428.

Fig. 199: Diagnostic Cable - VAS 5051/6A

 Connect Vehicle Diagnosis, Testing and Information System VAS 5051A --> Vehicle Diagnostic,
 In Vehicle Diagnostic, Testing and Information System VAS 5051A , select operating mode "Guided
Fault Finding".
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sequence:
 Chassis
 Distance regulation
 Functions
 Adaptation after replacing control module
FRONT SCAN DISTANCE MONITORING SYSTEM
General information
The Front Scan distance monitoring system is an expansion of the Adaptive Cruise Control (ACC) -->
Adaptive Cruise Control (ACC) and warns the driver in two levels before a collision with a vehicle ahead.
If the Distance Regulation Sensor G550 detects a possible collision, at speeds above 30 km/h, there is first a
warning with a symbol in the instrument cluster display and then a warning tone. At the same time, the vehicle
is prepared for possible emergency braking by the driver. To do this, the brake pads are applied to the brake
discs but without slowing the vehicle. In addition, the hydraulic brake assist reacts sensitively to the drivers
brake operation.
If the driver does not react to the warning, the Front Scan distance monitoring system intervenes with a brief
lurch through braking to bring attention to the collision risk - the vehicle speed is not reduced by this braking
lurch. The braking lurch only takes place in driving situations in which a danger should be avoided. In situations
in which it can be assumed that the driver is already alert, e.g. on tight curves or when the driver is braking, the
braking lurch is suppressed.
The Front Scan distance monitoring system is operated using the Adaptive Cruise Control Button E357 in the
turn signal lever and the instrument cluster display. While driving, important information is shown in the
instrument cluster display.
Distance Regulation Control Module J428 is equipped with On Board Diagnostics (OBD) which assists
troubleshooting.
The "Guided Fault Finding" function is to be used for troubleshooting of one of the systems described as in
chapter "Vehicle Diagnosis, Testing and Information System" --> Vehicle Diagnostic, Testing and
Information Systems.
Front Scan distance monitoring system components:

 Adaptive Cruise Control Button E357 in turn signal switch
Distance Regulation Control Module J428

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Distance Regulation Control Module J428 is mounted on front of vehicle, behind VW-logo in the radiator
protective grille.
components:

Distance Regulation Control Module J428 , removing and installing --> Distance Regulation Control Module
J428 , removing and installing
Adaptive Cruise Control Button E357
The Adaptive Cruise Control Button E357 is integrated in the turn signal switch on the steering column -->
Adaptive Cruise Control Button E357 , removing and installing.
90 - INSTRUMENTS
INSTRUMENT CLUSTER
Instrument cluster
NOTE:  Instrument cluster component functions can be checked On Board

Diagnostic (OBD) program function "Output Diagnostic Test Mode (DTM)"
--> Instrument cluster, Output Diagnostic Test Mode (DTM).
 Additional information:
Owners Manual
--> 01 - MAINTENANCE
The following components are integrated in the instrument cluster:
 Instrument Cluster Control Module J285

 Data Bus On Board Diagnostic Interface J533
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 Engine oil temperature display

 Tachometer
 Engine coolant temperature display

 Multi-function indicator
 Fuel gauge
 Speedometer
 Voltmeter
 Indicator lamps --> Instrument cluster indicator lamp symbol, vehicles through 11/06
All warning and indicator lamps are equipped with light-emitting diodes (LEDs) which cannot be serviced or
replaced separately. In the event of malfunctions, the complete instrument cluster must be replaced -->
Instrument cluster, replacing.
The instrument cluster is equipped with On Board Diagnostic (OBD) capabilities which assists with
troubleshooting.
Instrument cluster, replacing
Fault Finding".
sequence:
 Body
 01 - On Board Diagnostic (OBD) capable systems
 Instrument cluster
 Instrument cluster functions

 Instrument cluster, replacing
Instrument cluster, removing and installing
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Fig. 200: Release Lever T10039 & Wedge T10039/1

 Release lever T10039

 Wedge T10039/1
Removing:
NOTE:  Removal of the steering wheel is not necessary. To improve clarity, the
steering wheel is not shown in the following illustrations.
 If the instrument panel insert is to be replaced --> Instrument cluster,
replacing.
 Using the electrical or mechanical adjustment mechanism, fully extend and lower the steering wheel.
Fig. 201: Identifying Trim Strips & Locking Mechanisms

 Pry trim strips - 1 - and - 2 - out of locking mechanisms using wedge T10039/1.
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Fig. 202: Removing/Installing Upper Cover Piece Of Steering Column Components

 Remove bolts - 1 - from upper cover piece of steering column - 2 - and remove it.
 Remove instrument cluster shroud --> 68 - INTERIOR EQUIPMENT .
Fig. 203: Removing/Installing Bracket Of Instrument Cluster Visor & Bolt

 Remove bolts - 1 - from bracket of instrument cluster visor - 2 -.

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 Remove screws - 1 -.
Fig. 205: Removing/Installing Instrument Cluster Visor Bracket

 Remove bracket for instrument cluster visor - 1 - upward in - direction of arrow -.
Fig. 206: Identifying Instrument Cluster Harness Connectors

 Remove instrument cluster and disconnect harness connectors - 1 - on rear side of instrument cluster.
Installing:
 Place the instrument panel insert into the opening and connect the connectors.
 Install bracket for instrument cluster visor.
 After installing, test the functions of the instrument cluster.
Instrument cluster, Output Diagnostic Test Mode (DTM)

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The following components and functions can be checked via output Diagnostic Test Mode (DTM) of instrument
cluster:
 Speedometer G21
 Tachometer G5
 Fuel gauge G1
 Engine coolant temperature (ECT) gauge G3
 Oil Temperature Display Y12

 Supply Voltage Display Y11
 Segment test (During segment test, all segments of display unit are activated. For this, the display will be
activated in sequence in the colors white, red, green and blue.)
 Glow Plug Indicator Light K29
 Brake and Parking Brake Warning Lamp K7

 Safety Belt Warning Light K19
 Oil Pressure Warning Buzzer H11
 Gong (activation of gong in instrument cluster)
 Flasher acoustic (activation of flasher relay)
NOTE:  Above system/component checks depend on market version and installed

equipment.
Fault Finding".
sequence:
 Body
 Instrument cluster
 Instrument cluster functions

 Output Diagnostic Test Mode (DTM) of instrument cluster
Instrument cluster, rearview
NOTE:  Do not disassemble instrument cluster. In the event of malfunctions,

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replace complete instrument cluster.
Fig. 207: Identifying Connectors, 32-Pin

1 - Connector, 32-pin
 Blue
 Connector assignment, vehicles through 11/06 --> Instrument cluster connector assignment, vehicles
through 11/06
 Connector assignment, vehicles from 12/06 with monochrome display --> Electrical Wiring Diagrams,
Troubleshooting and Component Locations
 Connector assignment, vehicles from 12/06 with color display --> Electrical Wiring Diagrams,
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2 - Connector, 32-pin
 Green
 Connector assignment, vehicles through 11/06
 Connector assignment, vehicles from 12/06 with monochrome display --> Electrical Wiring Diagrams,
 Connector assignment, vehicles from 12/06 with color display --> Electrical Wiring Diagrams,
Instrument cluster connector assignment, vehicles through 11/06
NOTE:  Multi-pin connector assignments depend on market, vehicle equipment

and engine versions.
Connector, 32-pin, blue, vehicles through 11/06
Fig. 208: Connector, 32-Pin, Blue, Vehicles Through 11/06

1 - Terminal 15, positive
3 - Output signal 1 from electronic speedometer
4 - Tank sensor 2
5 - Tank sensor 1
6 - Low washer fluid level
7 - Terminal 31, sensor ground
8 - Terminal 30
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9 - Terminal 31, ground
10 - Oil pressure switch
11 - Ambient temperature
12 - Warning lamp for generator, terminal 61
13 - not in use
14 - not in use
15 - not in use
16 - not in use
17 - not in use
18 - Terminal 30 S
19 - Terminal 30 S
20 - not in use
21 - not in use
22 - Low coolant indicator
24 - Terminal 31, ground
25 - On-board diagnostics/K-line
26 - not in use
27 - not in use
28 - not in use
29 - Warning contact for brakes, general
30 - not in use
31 - Seat belt warning lamp
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32 - not in use
Connector, 32-pin, green, vehicles through 11/06
Fig. 209: Connector, 32-Pin, Green, Vehicles Through 11/06

1 - not in use
2 - not in use
3 - not in use
4 - not in use
5 - not in use
6 - not in use
7 - Brake lining wear
8 - CAN- out, high
9 - CAN- out, low
10 - not in use
11 - not in use
12 - not in use
13 - Parking brake
14 - not in use
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15 - not in use
16 - not in use
17 - not in use
18 - Signal for oil temperature and oil level warning
19 - Powertrain CAN-Bus, High
20 - Powertrain CAN-Bus, Low
21 - not in use
22 - not in use
23 - not in use
24 - not in use
25 - not in use
26 - not in use
27 - CAN-comfort, high
28 - CAN-comfort, low
29 - not in use
30 - Emergency operation
31 - CAN-infotainment High
32 - CAN-infotainment Low
Instrument cluster connector assignment, vehicles from 12/06 with monochrome display
Instrument cluster connector assignment, vehicles from 12/06 with monochrome display --> Electrical Wiring
Diagrams, Troubleshooting and Component Locations
Instrument cluster connector assignment, vehicles from 12/06 with color display
Instrument cluster connector assignment, vehicles from 12/06 with color display --> Electrical Wiring
Diagrams, Troubleshooting and Component Locations
Instrument cluster indicator lamp symbol, vehicles through 11/06

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NOTE:  Applicability and layout of instrument cluster warning and indicator lamps
are market and engine dependent.
 Different instrument clusters are used, depending on vehicle equipment.
Some lamps illustrated here may not apply to US/CDN models.
Fig. 210: Instrument Cluster Indicator Lamp Symbols, Vehicles Through 11/06
1 - Airbag or seatbelt tensioner system
2 - Seat belts
3 - Electronic Stability Program (ESP)
4 - ESP-system light (ASR/ESC)
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5 - Anti-lock braking system (ABS)
6 - Left/right turn signal indicator (turn signal/emergency flasher system)
7 - Rear fog lamps
8 - Trailer turn signals
9 - Lamp failure
10 - Offroad
11 - Generator load control
12 - Brake indicator/Parking brake indicator
13 - Fog lamps
14 - Tire pressure monitoring indicator
15 - High beam headlamp
16 - Rear fog lamps
17 - Shift lock
 Warning lamp only present in vehicles with automatic transmission
18 - Right turn signal indicator (turn signal/emergency flasher system)
19 - Left turn signal indicator (turn signal/emergency flasher system)
20 - Glow plug system
 Indicator lamp only present in vehicles with diesel engine
21 - Electronic power control (EPC)
 Indicator lamp only present in vehicles with gasoline engine
22 - Decoupled offroad stabilizer
23 - Cruise Control System
24 - Malfunction Indicator Lamp (MIL)
Instrument cluster indicator lamp symbol, vehicles from 12/06 with monochrome display
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Instrument cluster equipment versions: Highline
Fig. 211: Instrument Cluster Indicator Lamp Symbols, Vehicles From 12/06 With Monochrome Display
1 - Electronic Stabilization Program (ESP)
 Lit up: ESP damaged or manually switched off

 Blinking: ESP regulating
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2 - Anti-lock braking system (ABS)
3 - Operate footbrake
4 - EPC - Malfunction in gasoline engine
5 - Cruise control switched on
8 - Fog lights switched on
9 - Malfunction in generator
10 - Brake control light
 Brake fluid lever too low or

 Malfunction in brake system or
 Parking brake activated
11 - Engine malfunction (On Board Diagnostic)
12 - Daytime running lights switched on
13 - High beams switched on
 Airbag or belt tensioner system faulty or

 Passenger airbags switched off
15 - Lamp failure
 Lit up: Bulb failure

 Blinking: dynamic or static cornering light faulty
17 - Fasten seat belts!
18 - Lane change assistance (Side Scan) switched on
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19 - Distance control (Front Scan) switched on
Depending on equipment, some warning and indicator lights are also shown in the instrument cluster display.
Malfunctions are sorted according to priority and are shown in the display with red or yellow symbols and
additional information.
Instrument cluster indicator lamp symbol, vehicles from 12/06 with color display
Instrument cluster equipment versions: Premium
Fig. 212: Instrument Cluster Indicator Lamp Symbols, Vehicles From 12/06 With Color Display
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1 - Fasten seat belts!
2 - Electronic Stabilization Program (ESP)
 Lit up: ESP damaged or manually switched off

 Blinking: ESP regulating
3 - Anti-lock Braking System (ABS)/Electronic Differential Lock (EDS)
 Malfunction in ABS system

 Electronic differential lock (EDS) malfunction
6 - Lamp failure
 Lit up: Bulb failure

 Blinking: dynamic or static cornering light faulty
7 - Malfunction in generator
8 - Brake control light
 Brake fluid lever too low or

 Malfunction in brake system or
 Parking brake activated
10 - Daytime running lights switched on
11 - High beams switched on
13 - Operate footbrake
14 - EPC - Malfunction in gasoline engine
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15 - Engine malfunction (On Board Diagnostic)
 Airbag or belt tensioner system faulty or

 Passenger airbags switched off
Depending on equipment, some warning and indicator lights are also shown in the instrument cluster
display. Malfunctions are sorted according to priority and are shown in the display with red or yellow
symbols and additional information.
SERVICE INTERVAL INDICATOR
Service Reminder Indicator (SRI), resetting
 Resetting Service Reminder Indicator (SRI) --> 01 - MAINTENANCE .
92 - WINDSHIELD WIPER AND WASHER SYSTEM

FRONT WINDSHIELD WIPER SYSTEM
Front windshield wiper system

NOTE:  Windshield wiper system function can be checked via Wiper Motor Control
Module J400 output Diagnostic Test Mode (DTM).
Owners Manual
NOTE:  Hood (Front Hood Switch F266) must be closed to activate windshield
wiper functions.
Microsoft
Control Module for wiper motor J400 is integrated in Windshield Wiper Motor V.
NOTE:  If Control Module for wiper motor J400 or Windshield Wiper Motor V is
replaced, Control Module for wiper motor J400 must be coded.
Rain Sensor G213 or Rain/Light Recognition Sensor G397 may be installed, depending on equipment.
Rain Sensor G213 function is activated via Windshield Wiper/Washer Switch E22 --> Steering column switch
- assembly overview.
NOTE:  Observe notes for operation for Rain Sensor G213 Owners manual.
Rain Sensor G213 registers rain intensity which it converts to a corresponding signal. This signal is then
received by Control Module for wiper motor J400 and then transmitted to Windshield Wiper Motor V.
The Rain/Light Recognition Sensor G397 controls the Automatic Driving Lights Control (ADLC) function in
addition to the functions of Rain Sensor G213 listed above.
The ADLC (Automatic Driving Lights Control) function is activated via Light Switch E1 --> Light Switch E1 ,
removing and installing.
NOTE:  Observe notes for operation for "automatic driving lights control" Owners
manual.
The Rain/Light Recognition Sensor G397 also registers light intensity which it converts to a corresponding
signal. Wiper Motor Control Module J400 receives this signal first and then relays it via instrument cluster to
Vehicle Electrical System Control Module J519 , which switches the driving lights on.
Wiper Motor Control Module J400 and Vehicle Electrical System Control Module J519 are equipped with On
Board Diagnostic (OBD), which assists troubleshooting.
Front windshield wiper system, removing and installing
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Front windshield wiper system, removing
NOTE:  In order remove the wiper frame with linkages and wiper motor, wiper
arms and plenum chamber cover must be removed.
 Move the wiper into park position.

described in --> Battery, disconnecting and reconnecting. Not
adhering to sequence will result in the deactivation of Main Battery
Switch -E74- and subsequent damage to electrical system
components.
Wiper arm on drivers side, removing
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Fig. 214: Identifying Cover Cap

 Pry off cover cap - arrow - using a screwdriver.
Fig. 215: Loosening Mounting Nut

 Loosen mounting nut - arrow - but do not unscrew completely.

 Gently move wiper arm up and down until it can be removed from wiper arm shaft.
 Now unscrew mounting nut completely and pull wiper arm off wiper arm shaft.
Wiper arm on passengers side, removing
NOTE:  Only the wiper arm shaft depicted at right in illustration is driven.
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Fig. 216: Identifying Wiper Arm Axle & Shaft Mounting Nuts
 Remove mounting nut - 1 - from wiper arm axle.

 Remove mounting nut - 2 - from wiper arm shaft.
Fig. 217: Identifying Wiper Arm Axle & Wiper Arm

 Remove washer - 1 - from wiper arm axle.

 Move wiper arm - 2 - lightly up and down until cone - 3 - can be pulled off wiper arm - 2 -.
 Remove wiper arm.
Plenum chamber cover, removing
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Fig. 218: Identifying Plenum Chamber Cover Retainers

 Release the retainers - arrows - of the plenum chamber cover by turning them 90°.
 Carefully lift cover - 1 - slightly until harness connector for Sensor for air quality G238 can be
disconnected.
 Remove the cover.
NOTE:  Plenum chamber cover is inserted below windshield in a guide rail.

 For reasons of clarity, illustration shows plenum chamber already
removed.
Fig. 219: Loosening Twist Locks

 Loosen twist locks - 1 - of cover by a 90° turn.

 Carefully unclip plenum chamber cover upward - arrows -.
Wiper frame with linkage and Windshield Wiper Motor V , removing
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Fig. 220: Identifying Hex Socket Head Bolt

 Remove hex socket head bolt M6 - 1 - and remove washer.
Fig. 221: Removing/Installing Bolts

 Remove bolts - 1 -.
Fig. 222: Identifying Wire Retainers & Hex Socket Head Bolts
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 Unclip wire retainer - 1 - from wiper frame.

 Disconnect connector at Windshield Wiper Motor V.
CAUTION:  Connector catches can be destroyed.

 Connector catches must not be loosened by force.
 Remove hex socket head bolts M6 - 2 - and remove washers.

 Remove complete wiper frame.
Removing Windshield Wiper Motor V from wiper frame
Fig. 223: Removing/Installing Hex Nut & Crank

 Remove hex nut - 1 -.

 Remove crank - 2 - from wiper motor shaft.
Fig. 224: Identifying Windshield Wiper Motor Mounting Bolts

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 Remove mounting bolts - arrows - for Windshield Wiper Motor V.

 Remove Windshield Wiper Motor V from wiper frame.
Installing Windshield Wiper Motor V into wiper frame
Fig. 225: Identifying Windshield Wiper Motor Mounting Bolts

 Insert Windshield Wiper Motor V into wiper frame and secure it with mounting bolts - arrows -.
Windshield wiper and washer system.
 Let Windshield Wiper Motor V run to rest position, to do so, connect connector to Windshield Wiper
Motor V and operate windshield wiper switch briefly to do so.
wiper functions.
 Place crank - 2 - onto shaft of Windshield Wiper Motor V , the distance - A - between crank - 2 - and pin
- 3 - must be 4 mm.
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Fig. 226: Identifying Crank, Pin & Windshield Wiper Motor

 Thread on crank - 2 - with hex nut - 1 -.

 Tighten hex nut - 1 - to specified tightening torque --> Tightening Torques: Windshield wiper and
washer system.

components.
Wiper frame with linkage and Windshield Wiper Motor V , installing

components.

 Let Windshield Wiper Motor V run to rest position, to do so, connect connector to Windshield Wiper
Motor V and operate windshield wiper switch briefly to do so.
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wiper functions.
 Install wiper frame with linkage and Windshield Wiper Motor V in reverse order of removal.
 Tighten hex socket head bolts M6 for wiper frame with linkage to specified tightening torque -->
Tightening Torques: Windshield wiper and washer system.
Plenum chamber cover, installing
 Install plenum chamber cover in reverse sequence.
Wiper arms, installing
 Place wiper arms for drivers side and passengers side on their shafts.
 Screw mounting nut loosely onto wiper arm shaft of drivers side.
Fig. 227: Identifying Wiper Arm Axle & Wiper Arm

 Install disc - 1 - on wiper arm shaft.

 Insert cone - 3 - into wiper arm - 2 -.
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Fig. 228: Identifying Wiper Arm Axle & Shaft Mounting Nuts
 Screw mounting nut - 2 - loosely onto wiper arm shaft of passengers side.
NOTE:  Mounting nut - 2 - of wiper arm shaft must only be tightened after
adjusting windshield wiper blade end position.
 Thread on mounting nut - 1 - for wiper arm axle of passengers side.

 Tighten mounting nut - 1 - of wiper arm axle of passengers side to specified tightening torque -->
Tightening Torques: Windshield wiper and washer system.
 Adjust windshield wiper blade park position --> Park position of windshield wiper blades, adjusting.
Wiper arms, removing and installing
Removing:
Removing wiper arm on drivers side.
Removing wiper arm on passengers side.
Installing:
Installing wiper arms.
Park position of windshield wiper blades, adjusting
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Fig. 230: Identifying Wiper Blade (Drivers Side)

Driver side:
The distance - A - between wiper blade and lower edge of windshield must be 44 mm.
The distance - B - between wiper blade and lower edge of windshield must be 12 mm.
 If necessary, adjust the park position by repositioning the wiper arm.

 Tighten drivers side wiper arm mounting nut to specified tightening torque --> Tightening Torques:
Windshield wiper and washer system.
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Fig. 231: Identifying Wiper Blade (Passenger Side)

Passenger side:
The distance - A - between wiper blade and lower edge of windshield must be 12 mm.
The distance - B - between wiper blade and lower edge of windshield must be 9 mm.
 Adjust the rest position by loosening the cone and shifting the wiper arm, if necessary.
 Tighten mounting nut for passengers side wiper arm to specified tightening torque --> Tightening
Torques: Windshield wiper and washer system.
Aero wipers, removing and installing
Removing:
NOTE:  Right and left wiper blades may not be interchanged during installation.
 Aero-wipers are very flexible. Grasp wiper blades only in area of wiper
blade mount to lift them off front windshield.

 Fold up wiper arm.
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Fig. 232: Removing Aero Windshield Wipers

 Turn wiper blade - 1 - on wiper arm until it reaches stop - arrow A -.

 Pull off wiper blade - 1 - from wiper arm axle - arrow B -.
Installing:
 Slide wiper blade onto axle of wiper arm.

 Turn wiper blade on wiper arm axle until it reaches stop.
 Carefully fold wiper arm back onto windshield.
Rain Sensor G213 and Rain/Light Recognition Sensor G397 , removing and installing
NOTE:  Removing and installing Rain Sensor G213 and Rain/Light Recognition
Sensor G397 is identical.
 Depending on vehicle equipment (windshield tint), different sensors are
installed .
Removing:
 Remove interior mirror --> 68 - INTERIOR EQUIPMENT .
Microsoft
Fig. 233: Rain/Light Recognition Sensor G397 And Harness Connector

 Disconnect harness connector - 1 - from Rain Sensor G213 or Rain/Light Recognition Sensor G397 - 2 -.
Fig. 234: Rain/Light Recognition Sensor G397 And Retaining Plate

 Using e.g. a screwdriver, pry Rain Sensor G213 or Rain/Light Recognition Sensor G397 - 1 - out of
bracket - 2 -.
NOTE:  When removing, make sure to pry off complete Rain Sensor G213 or
Rain/Light Recognition Sensor G397 and not only the upper casing of Rain
Sensor G213 or of Rain/Light Recognition Sensor G397.
Installing:
NOTE:  Always clean windshield surface inside bracket for Rain Sensor G213 or
Rain/Light Recognition Sensor G397 before installing.
 Surface (connecting pads) of Rain Sensor G213 or Rain/Light Recognition
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Sensor G397 must not be soiled when installing.

 If the surface (connecting pads) of Rain Sensor G213 or Rain/Light
Recognition Sensor G397 is soiled, it may be possible to clean it by
"applying" and then "removing" one or more adhesive strips.
 After installing Rain Sensor G213 or Rain/Light Recognition Sensor G397 ,
there must be no air bubbles between windshield and surface (connecting
pads).
Control Module for wiper motor J400
Control Module for wiper motor J400 , removing and installing
Wiper Motor Control Module J400 is integrated with Wiper Motor V and cannot be replaced separately.
 Wiper Motor V , removing and installing --> Front windshield wiper system, removing and installing.
Control Module for wiper motor J400 , coding
Fault Finding".
sequence:
 Body
 Wiper electronics
 Functions of wiper electronics

 Control Module for wiper motor, coding
Control Module for wiper motor J400 , output Diagnostic Test Mode (DTM)
Fault Finding".
sequence:
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 Body
 Wiper electronics
 Functions of wiper electronics

 Output Diagnostic Test Mode (DTM) of wiper electronics
WINDSHIELD WASHER SYSTEM
Windshield washer system
NOTE:  Front windshield washer system function can be checked via Vehicle
Electrical System Control Module J519 Output Diagnostic Test Mode.
Owners Manual
Vehicle Electrical System Control Module J519 is equipped with On Board Diagnostics (OBD) which assists in
troubleshooting.
Front windshield washer system - assembly overview
Microsoft
Fig. 235: Front Windshield Washer System - Assembly Overview

1 - Windshield washer system reservoir filler tube
 Removing and installing filler tube.
2 - Y-piece
 Divides washer fluid line to washer nozzles of front windshield washer system
3 - Angle coupling
 Connection to right washer nozzle

 Washer hose couplings, overview --> Washer Hose Couplings
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4 - Right washer nozzle
 Depending on equipment, with Right Washer Nozzle Heater Z21

 Only height adjustable --> Washer nozzles for front windshield washer system, adjusting
 Removing and installing --> Washer nozzles for front windshield washer system, removing and
installing
5 - Hose
 Hose repair --> Washer hoses, repairing
6 - Angle coupling
 Connection to left washer nozzle

7 - Left washer nozzle
 Depending on equipment, with Left Washer Nozzle Heater Z20

 Only height adjustable --> Washer nozzles for front windshield washer system, adjusting
 Removing and installing --> Washer nozzles for front windshield washer system, removing and
installing
8 - Windshield and Rear Window Washer Pump V59
 Removing and installing --> Windshield and Rear Window Washer Pump V59 , removing and
installing
 Checking
9 - Angle coupling
 Connection to front and rear window washer pumps

10 - Windshield Washer Fluid Level Sensor G33
 Removing and installing --> Windshield Washer Fluid Level Sensor G33 , removing and installing
11 - Washer fluid reservoir
 Removing and installing --> Washer fluid reservoir, removing and installing
Washer fluid reservoir, removing and installing
Tank for windshield washer system and headlamp cleaning system is in two parts.
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Tank for windshield washer system and headlamp cleaning system, removing and installing.
Filler tube for tank for windshield washer system and headlamp cleaning system, removing and installing.
Washer fluid reservoir, removing and installing
NOTE:  In order to prevent interchanging washer fluid line connections at

Windshield and Rear Window Washer Pump V59 , connections at pump
and hose lines are color-coded. Hose connector pieces must be connected
to the corresponding colored pump connections during installation.
Removing:
 Remove front right wheel housing liner. --> 66 - EXTERIOR EQUIPMENT .
Fig. 236: Removing/Installing Wheel Housing Tank Components

 Remove mounting bolts - 2 - for tank - 1 - in wheel housing.
Fig. 237: Remove/Install Electrical Multi-Pin Harness Connector Components

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 Disconnect electrical multi-pin harness connector - 1 - of Windshield and Rear Window Washer Pump
V59.
Fig. 238: Removing/Installing Windshield & Headlamp Washer System Reservoir Components
 Remove windshield and headlamp washer system reservoir - 1 - back - arrow - from filler tube - 2 -.
 Place tank - 1 - on front tire.
Fig. 239: Removing/Installing Hose From Tank & Disconnecting It From Headlamp Washer Pump
 Unclip hose - 1 - from tank - arrows - and disconnect it from Headlamp Washer Pump V11 - 2 -.
 Drain windshield and headlamp washer system reservoir and collect fluid.
 Disconnect multi-pin harness connector at Headlamp Washer Pump V11 - 2 -.
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Fig. 240: Removing/Installing multi-pin harness connector Components

 Disconnect multi-pin harness connectors at Windshield Washer Fluid Level Sensor G33 - 1 - and at
Windshield and Rear Window Washer Pump V59 - 2 -.
 Release and disconnect angle connecting pieces - 3 - and - 4 - from Windshield and Rear Window
Washer Pump V59 - 2 -.
 Remove windshield and headlamp washer system reservoir from wheel housing.
Installing:
 Angled connecting pieces - 3 - and - 4 - are color-coded and must be allocated to the corresponding color
connections of Windshield and Rear Window Washer Pump V59 when installing.
 Bleed headlamp washer system after completing assembly work --> Headlamp washer system,
ventilating.
Filler tube for tank for windshield washer system and headlamp cleaning system, removing and installing
Removing:
Fig. 241: Identifying Filler Tube

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 Before filler tube - 1 - of tank can be removed, front right fender must be removed --> 50 - BODY -
FRONT .
 Remove mounting bolt - arrow - for filler tube - 1 -.
 Turn filler tube - 1 - upward and remove it forward out of windshield and headlamp washer system
reservoir.
Installing:
Install in reverse order of removal.
Windshield and Rear Window Washer Pump V59 , removing and installing
The Windshield and Rear Window Washer Pump V59 is installed on windshield washer and headlamp cleaning
system tank in right wheel housing.
Removing:
 Remove tank for windshield washer system and headlamp cleaning system.
Fig. 242: Identifying Rear Window Washer Pump

 Remove Windshield and Rear Window Washer Pump V59 - 1 - from tank - arrow -.
Installing:
ventilating.
Windshield Washer Fluid Level Sensor G33 , removing and installing

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Removing:
 Remove tank for windshield washer system and headlamp cleaning system --> Washer fluid reservoir,
Fig. 243: Removing/Installing multi-pin harness connector Components

 Disconnect harness connector - 1 - and pull Windshield Washer Fluid Level Sensor G33 out of its rubber
seal.
Installing:
ventilating.
Washer nozzles for front windshield washer system, removing and installing
CAUTION: Do not use solid objects to clean the washer nozzles!
NOTE:  Washer nozzles are pre-adjusted and can only be adjusted in height.
 In the event contamination in washer nozzle produces an uneven spray
pattern, remove washer nozzle and rinse it with water in the opposite
direction of spray. It is permissible to further blow through in opposite
direction of spray with compressed air.
Removing:
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Fig. 244: View Of Washer Nozzles For Front Windshield Washer System
 To remove washer nozzle, press jet to the side from left and remove toward front out of hood.
 Disconnect hose and harness connector for Left Washer Nozzle Heater Z20 and Right Washer Nozzle
Heater Z21 from washer nozzle.
Installing:
 To install, connect hose and harness connector for Left Washer Nozzle Heater Z20 or for Right Washer
Nozzle Heater Z21.
 Insert wash into installation opening and let it engage.
 Check and adjust washer jets --> Washer nozzles for front windshield washer system, adjusting.
Washer nozzles for front windshield washer system, adjusting
CAUTION:  Danger of damage.

 Washer nozzle may be damaged.
 Do not use solid objects to clean the washer nozzles!
NOTE:  In the event contamination in washer nozzle produces an uneven spray

pattern, remove washer nozzle and rinse it with water in the opposite
direction of spray. It is permissible to further blow through in opposite
direction of spray with compressed air. Do not use solid objects to clean
the washer nozzles!
Adjusting washer nozzles for front windshield washer system --> 01 - MAINTENANCE .
REAR WINDOW WIPER SYSTEM
Rear window wiper system
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NOTE:  The function of rear window wiper and washer system can be checked via
Comfort System Central Control Module J393 output Diagnostic Test Mode
(DTM).
Comfort System Central Control Module J393 is equipped with On Board Diagnostics (OBD) which assists
troubleshooting.
Rear window wiper, removing and installing
Rear window wiper arm, removing and installing
NOTE:  Rear window must remain closed when removing and installing.

Removing:
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NOTE:  Vehicles through 01/05 and from 02/05 have a different cover cap - 1 - over
the wiper arm mounting nut.
Vehicles through 01/05:
Fig. 246: Identifying Rear Window Wiper Cover Cap

 Unclip rear window wiper cover cap - 1 - downward - arrow -.
Vehicles from 02/05:
Fig. 247: Pressing Cover Cap

 Press cover cap - 1 - up until it releases - arrow -.
Continuation for all vehicles:
 Remove cover cap - 1 - straight back from rear window wiper arm.
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Fig. 248: Identifying Hex Nut & Wiper Arm

 Loosen hex nut - arrows - but do not remove it completely.

 Fold wiper arm up - 2 - and loosen it from cone using sideways motions.
 Remove hex nut - 1 - completely and pull wiper arm - 2 - off wiper arm shaft.
Installing:
 Install wiper arm in reverse order of removal and set the rear window wiper rest position --> Rear
window wiper blade park position, adjusting.
Motor for rear window wiper V12 , removing and installing
NOTE:  Rear window must remain closed when removing and installing.
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Removing:

 Remove lower trim for tailgate --> 70 - INTERIOR TRIM .
Fig. 250: Removing/Installing Rear Window Wiper Motor Components

 Disconnect connector - 1 - from Rear Window Wiper Motor V12 - 3 -.

 Remove nuts - 2 -.
 Remove Motor for rear window wiper V12 - 3 -.
Installing:
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Fig. 251: Identifying Drive Pin & Control Disc

Motor for rear window wiper V12 must be aligned during installation so that drive pin - 1 - of eccentric lever
engages in hole - arrow - of control disc.
NOTE:  If the position of drive pin - 1 - on eccentric lever does not line up to
control disc on Rear Window Wiper Motor V12 - 2 - - arrow - , turn wiper
arm shaft from outside. Do not twist control disc of Rear Window Wiper
Motor V12 - 2 - under any circumstances.
Fig. 252: Removing/Installing Rear Window Wiper Motor

 Place the Motor for rear window wiper V12 - 2 - on rear lid so that drive pin of eccentric engages in
control disc on Motor for rear window wiper V12 - 2 -.
 Center Motor for rear window wiper V12 - 2 - to window module - arrow - using a suitable centering
drift with 5 mm diameter.
NOTE:  As a centering drift, e.g. a commercially available drill with a diameter of 5

mm and a length of at least 75 mm can be used. When using a drill, there
must be no burrs on the shaft.
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Fig. 253: Removing/Installing Rear Window Wiper Motor

 Bolt Motor for rear window wiper V12 - 2 - with hex nuts - 1 - to the rear lid.
 Tighten hex nuts - 1 - to specified tightening torque --> Tightening Torques: Windshield wiper and
washer system.
 Install lower trim for tailgate --> 70 - INTERIOR TRIM .
 Install wiper arm.
Rear window wiper blade park position, adjusting

 Let wiper run to rest position.
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Fig. 255: Checking Distance Between Wiper Blade And Lower Edge Of Windshield
The distance - a - between wiper blade and lower edge of windshield must be 55 mm.
 If necessary, adjust the park position by repositioning the wiper arm.
Fig. 256: Identifying Hex Nut & Wiper Arm

 Tighten mounting nut - 1 - to specified tightening torque --> Tightening Torques: Windshield wiper
and washer system.
Aero wipers, removing and installing
Removing:

 Fold the wiper arm upward, holding the wiper blade where it is connected to the wiper arm.
Thereby, any unwanted bending of the wiper arm and blade is prevented.
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 Release slider on wiper blade and fold up wiper blade until it reaches stop.
 Pull off the wiper blade.
Installing:
Fig. 257: Identifying Wiper Blade & Axis On Wiper Arm

 Slide wiper blade - 1 - on axis on wiper arm - arrow A -.

 Fold back wiper blade - arrow B - , lock slider on wiper blade and carefully fold wiper arm back on to
rear windshield.
REAR WINDOW WASHER SYSTEM
Rear window washer system
NOTE:  The function of rear window wiper and washer system can be checked via
Comfort System Central Control Module J393 output Diagnostic Test Mode
(DTM).
troubleshooting.
Rear window washer system, assembly overview
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Fig. 258: Identifying Rear Window Washer System

1 - Coupling
 Separating point between engine compartment wiring harness and roof wiring harness
2 - Coupling
 Separating point between roof wiring harness and rear lid wiring harness
3 - Angle coupling
 Connection to washer nozzle of rear window washer system

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4 - Washer nozzle of rear window washer system
 Washer nozzles, replacing --> Washer nozzle, replacing
5 - Windshield and Rear Window Washer Pump V59
 Removing and installing --> Windshield and Rear Window Washer Pump V59 , removing and
installing
 Checking
6 - Hose
 Hose repair --> Washer hoses, repairing
7 - Angle coupling
 Connection to front and rear window washer pumps

8 - Windshield Washer Fluid Level Sensor G33
 Removing and installing --> Windshield Washer Fluid Level Sensor G33 , removing and installing
Washer nozzle, replacing
Washer nozzle is a component of High-mount Brake Light M25 and cannot be replaced separately. If washer
nozzle must be replaced, High-mount Brake Light M25 must also be replaced.
 High-mount Brake Light M25 , removing and installing --> High-mount Brake Light M25 , removing
and installing.
Adjusting washer nozzle
Washer nozzle is a component of High-mount Brake Light M25 and cannot be adjusted.
NOTE:  If wash sprays unevenly or does not spray the wiper area, replace High-
mount Brake Light M25 with wash (repair measure).
 High-mount Brake Light M25 , removing and installing --> High-mount Brake Light M25 , removing
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and installing.
HEADLAMP CLEANING SYSTEM
Headlamp cleaning system
NOTE:  Headlamp cleaning system function can be checked via output Diagnostic
Test Mode (DTM) of Vehicle Electrical System Control Module J519.
 Activation time period and delay time up to activation of Headlamp Washer
Pump V11 can be adjusted.
Owners Manual
After switching the ignition on, headlamp lenses are also cleaned on first operation and then on every fifth
operation of windshield wiper lever. To do this, windshield wiper lever must be pulled toward steering wheel
for a minimum of 0.5 seconds with low-beam or high-beam headlamps switched on.
After assembly work or when first operating headlamp cleaning system, it must be ventilated to ensure proper
function --> Headlamp washer system, ventilating.
Vehicle Electrical System Control Module J519 is equipped with On Board Diagnostics (OBD) which assists in
troubleshooting.
Headlamp washer system, component overview
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Fig. 259: Headlamp Washer System, Component Overview

1 - Headlamp Washer Pump V11
 Removing and installing --> Headlamp Washer Pump V11 , removing and installing
 Checking
 Adjusting activation time and delay time up to activation
2 - Angle coupling
 Connection to Headlamp Washer Pump

3 - Lift cylinder for left wash
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 Washer jet telescopic cylinder, removing and installing --> Lift cylinder for washer jets, removing and
installing
 Removing and installing wash holder --> Washer nozzle holder, removing and installing
 Adjusting wash --> Washer nozzles for headlamp cleaning system, adjusting
4 - Connecting piece
 Connection to lift cylinder for left washer nozzle

5 - Hose
 S 10 x 3 mm
6 - Lift cylinder for right wash
 Washer jet telescopic cylinder, removing and installing --> Lift cylinder for washer jets, removing and
installing
 Removing and installing wash holder --> Washer nozzle holder, removing and installing
 Adjusting wash --> Washer nozzles for headlamp cleaning system, adjusting
7 - Angle coupling
 Connection to lift cylinder for right washer nozzle

8 - Y-piece
 Divides washer fluid line to washer nozzle lift cylinders
9 - Filler tube for tank for windshield washer system and headlamp cleaning system
 Removing and installing
Headlamp Washer Pump V11 , removing and installing
Headlamp Washer Pump V11 is installed at windshield washer fluid reservoir and headlamp cleaning system in
right wheel housing.
Removing:
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 Remove tank for windshield washer system and headlamp cleaning system.
Fig. 260: Removing/Installing Headlamp Washer Pump Harness Connector

 Disconnect harness connector - 1 - at Headlamp Washer Pump V11 - 2 -.

 Turn Headlamp Washer Pump V11 - 2 - in tank so that hose connection of Headlamp Washer Pump V11
points upward.
 Remove Headlamp Washer Pump V11 - 2 - from tank - arrow -.
Installing:
ventilating.
Lift cylinder for washer jets, removing and installing
Removing:
 Remove front bumper cover --> 63 - BUMPERS .
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Fig. 261: Pulling Out Wash Until It Reaches Stop And Uncliping Cover Cap From Pins
 Pull out wash until it reaches stop and unclip cover cap - 1 - from pins - arrows -.
Fig. 262: Removing/Installing Mounting Bolts Of Lift Cylinder And Remove Lift Cylinder From Pins
 Remove mounting bolts - 2 - of lift cylinder - 3 - and remove lift cylinder from pins - 1 - - arrows -.
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Fig. 263: Connecting/Disconnecting Washer Hose Coupling (Headlight Cleaning System)

 To loosen hose connection, press securing clip - 1 - - arrow - and disconnect hose connection.
 Remove lift cylinder.
Installing:
ventilating.
Washer nozzle holder, removing and installing
NOTE:  Washer nozzle holder can also be removed and installed with bumper
installed.
Removing:
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Fig. 264: Pulling Out Wash Until It Reaches Stop And Uncliping Cover Cap From Pins
 Pull out wash until it reaches stop and unclip cover cap - 1 - from pins - arrows -.
Fig. 265: Identifying Securing Clip

 Lift securing clip - arrow - slightly with a small screwdriver.

 Pull out washer nozzle bracket.
Installing:
ventilating.
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Washer nozzles for headlamp cleaning system, adjusting
 Washer nozzles for headlamp cleaning system, adjusting --> 01 - MAINTENANCE .
Headlamp washer system, ventilating
After assembly work or when first operating, headlamp cleaning system must be ventilated to ensure proper
function.
 Fill tank for window washer system and headlamp cleaning system.
 Start the engine.
 Switch headlamps to "ON".
 Operate headlamp cleaning system several times (3-5 impulses for every 3 second period).
 If necessary, repeat this ventilation procedure until proper function of lift cylinders and washer nozzles is
obtained.
WASHER HOSE COUPLINGS
Washer Hose Couplings
WASHER HOSES, REPAIRING
Washer hoses, repairing
TIGHTENING TORQUES: WINDSHIELD WIPER AND WASHER SYSTEM
Tightening Torques: Windshield wiper and washer system
Fasteners Tightening torques

Windshield Wiper Motor V to 7 Nm
wiper frame
Crank to wiper motor shaft 20 Nm
Wiper frame with linkage to body M6 10 Nm
Wiper arm axle, passengers side 15 Nm
Drivers side wiper arm 32 Nm
Wiper arm, passenger side 32 Nm
Rear window wiper arm 12 Nm
Motor for rear window wiper V12 7 Nm
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to rear lid
94 - LIGHTS, SWITCHES - EXTERIOR

MAIN HEADLAMPS
Main headlamps
NOTE:  Always switch off headlamps and remove ignition key before working on
headlamps.
 Familiarity with the function and operation of the lighting system is
essential in the event of customer complaints.
Owners Manual
Vehicle electrical system control is equipped with On Board Diagnostics (OBD) which assists troubleshooting
of main headlamps.
Headlamps - assembly overview
NOTE:  After performing work which affects headlamp adjustment, check

headlamp adjustment and adjust headlamps if necessary. --> 01 -
MAINTENANCE .
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Fig. 266: Headlamps - Assembly Overview

- Tightening torques --> Tightening Torques: Headlamp
1 - Left Headlamp Beam Adjustment Motor V48 and Right Headlamp Beam Adjusting Motor V49
 Removing and installing --> Automatic headlamp range control adjusting motor, removing and
installing
2 - Screws
 For Left Headlamp Beam Adjusting Motor V48 and Right Headlamp Beam Adjusting Motor V49
3 - Cover
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4 - Left Low Beam Headlamp M29 and Right Low Beam Headlamp M31
 Lamp H7LL 12 V, 55 W
 Replacing
 Checking
5 - Left High Beam Headlamp M30 and Right High Beam Headlamp M32
 Lamp H9 12 V, 65 W
 Replacing
 Checking
6 - Cover
7 - Cover
8 - Lamp socket with grip piece
 For Left Front Turn Signal Light M5 and Right Front Turn Signal Light M7
9 - Left Parking Lamp M1 and Right Parking Lamp M3
 Lamp 12 V, W 5 W LL (for RoW models)

 Lamp 12 V, WY 5 W (for North American models, colored orange)
 Replacing
 Checking
10 - Left Front Turn Signal Lamp M5 and Right Front Turn Signal Lamp M7
 Lamp 12 V, PY 21 W Diadem
 Replacing
 Checking
11 - Headlamp
 Removing and installing --> Headlamps, removing and installing

 Headlamp position, correcting --> Headlamp installation position, correcting
 Perform basic setting of headlamp --> 01 - MAINTENANCE
12 - Adjustment bushing
13 - Screws
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 For front headlamp mount
14 - Headlamp mount
 Removing and installing left headlamp mount, vehicles with 6-cyl. fuel injection engine
 Removing and installing left headlamp mount, vehicles with 10-cyl. TDI engine and 8-cyl. fuel injection
engine
 Removing and installing right headlamp mount, vehicles with 6-cyl. fuel injection engine
 Removing and installing right headlamp mount, vehicles with 10-cyl. TDI engine and 8-cyl. fuel injection
engine
15 - Securing clip
16 - Locking bolt
17 - Bushing
18 - Screws
 For rear headlamp mount
19 - Connector
20 - Securing clip
21 - Adjusting shaft for high beam lateral adjustment
22 - Adjusting shaft for dip and high beam height adjustment
23 - Screws
 For adjusting shafts
Headlamps, removing and installing
NOTE:  It is not necessary to disconnect battery.

 Illustrations depict removal and installation of left headlamp.
Removing:
 Press against headlamp.
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Fig. 267: Turning Locking Bolt In Direction Of Arrow Open (Sticker)

 Turn locking bolt - arrow - in - direction of arrow Open (sticker) - until resistance is felt.
NOTE:  Do not use force to turn bolt further, otherwise the locking mechanism will
be destroyed.
Headlamp is pushed toward front.
 Pull headlamp out of opening on body until resistance is felt.
Fig. 268: Identifying Locking Clip

 Hold locking clip - 1 - pressed - arrow - and remove headlamp from opening on body.
Installing:
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Fig. 269: Identifying Guides

NOTE:  Guides - arrows - must be free of dirt.
 Check connector - 1 - in headlamp mount for proper fitting before inserting headlamp into guides.
 Set headlamp into guides - arrows -.
 Slide headlamp into opening on body.
NOTE:  A significant "clicking" must be audible. Securing clip engages.
Fig. 270: Turning Locking Bolt In Direction Of Arrow Open (Sticker)

 Turn locking bolt - arrow - in - direction of arrow Close (sticker) - until resistance is felt.
 Press lightly against headlamp and turn further in - direction of Close arrow (sticker) -.
Securing bracket must engage audibly.
NOTE:  Do not use force to turn bolt further, otherwise the locking mechanism will
be destroyed.
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 Check installation position of headlamp for uniform gap dimensions.
If the gaps are uneven in relation to body, headlamp position must be corrected --> Headlamp installation
position, correcting.
 Check headlamp for function.

 Check and adjust headlamp aim if necessary --> 01 - MAINTENANCE .
Headlamp mount, removing and installing
Removing and installing left headlamp mount, vehicles with 6-cyl. fuel injection engine.
Removing and installing left headlamp mount, vehicles with 10-cyl. TDI engine and 8-cyl. fuel injection
engine.
Removing and installing right headlamp mount, vehicles with 6-cyl. fuel injection engine.
Removing and installing right headlamp mount, vehicles with 10-cyl. TDI engine and 8-cyl. fuel injection
engine.
Left headlamp mount - vehicles with 6-cyl. fuel injection engine, removing and installing

Removing:
 Remove headlamp --> Headlamps, removing and installing.
 Move the lock carrier to the service position --> 50 - BODY - FRONT .
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Fig. 273: Identifying Headlamp Mount Connector

 Disconnect connector - arrow - , at rear side of headlamp mount.
Fig. 274: Identifying Line Guides

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 Loosen line - 1 - out of line guides - arrows - and press it downward.
Fig. 275: Removing/Installing Headlamp Mount Screws


 Remove headlamp mount.
Installing:

 Tighten mounting bolts - arrows - on front headlamp mount to specified tightening torque -->
Tightening Torques: Headlamp.
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 Tighten mounting bolts - arrows - on rear of headlamp mount to specified tightening torque -->
NOTE:  If headlamp mount is removed, headlamp must always be adjusted after

installation.
Left headlamp mount - vehicles with 10-cyl. TDI engine and 8-cyl. fuel injection engine, removing and installing

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Removing:
 Move the lock carrier to the service position --> 50 - BODY - FRONT .

Vehicles with diesel engine:
 Remove left air filter housing --> 23 - DIESEL FUEL INJECTION .
Vehicles with fuel injection engine:
 Remove left air filter housing -->

 24 - MULTIPORT FUEL INJECTION (MFI) for 3.2L V6 4V ENGINE MECHANICAL, FUEL
 24 - MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 4V ENGINE MECHANICAL,
FUEL INJECTION IGNITION, ENGINE CODE(S): BAR
FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX
.
Continued for all vehicles:
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Fig. 280: Identifying Headlamp Mount Connector

 Disconnect connector - arrow - , at rear side of headlamp mount.
Fig. 281: Identifying Line Guides

 Loosen line - 1 - out of line guides - arrows - and press it downward.

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 Remove headlamp mount.
Installing:

 Tighten mounting bolts - arrows - on front headlamp mount to specified tightening torque -->

 Tighten mounting bolts - arrows - on rear of headlamp mount to specified tightening torque -->
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installation.
Right headlamp mount - vehicles with 6-cyl. fuel injection engine, removing and installing
Headlamp mount and attachments are arranged symmetrically on the left side.
Removing and installing right headlamp mount for vehicles with 6-cyl. fuel injection engine is performed as for
removing and installing left headlamp mount for vehicles with 6-cyl. fuel injection engine, note the following
when doing so:
Removing:
 Remove air filter housing -->

FUEL INJECTION IGNITION, ENGINE CODE(S): BAR
FUEL INJECTION IGNITION, ENGINE CODE(S): AXQ, BHX
.
Right headlamp mount - vehicles with 10-cyl. TDI engine and 8-cyl. fuel injection engine, removing and installing
Headlamp mount and attachments are arranged symmetrically on the left side.
Removing and installing right headlamp mount for vehicles with 10-cyl. TDI-engine and 8-cyl. fuel injection
engine is performed as for removing and installing left headlamp mount for vehicles with 10-cyl.TDI-engine
and 8-cyl. fuel injection engine.
Headlamp installation position, correcting
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NOTE:  Illustrations depict left headlamp.
If during the check of the final installation position it is established that headlamp gaps are uneven with the
body, correct installation position as follows:
Fig. 286: Identifying Mounting Bolts & Bumper Cover

 Remove mounting bolts - arrows - for guide profile of bumper cover - 1 -.

 Remove guide profile of bumper cover - 1 -.
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Fig. 287: Identifying Front Mounting bolts

 Loosen the two front mounting bolts - arrows - far enough until headlamp mount with headlamp can be
moved back and forth lightly in adjustment bushings.
Fig. 288: Identifying Adjustment Bushing

 Adjust the gap dimension by turning the adjustment bushing - arrow - in or out.
 Tighten mounting bolts on front headlamp mount to specified tightening torque --> Tightening Torques:
Headlamp.
 Check and, if necessary, correct headlamp position again for uniform gap dimension.
 Install guide profile of bumper cover.
 Install front bumper cover: Bumper cover, > 10.2006 --> 63 - BUMPERS or Bumper cover, 11.2006 > --
> 63 - BUMPERS
NOTE:  If a headlamp is adapted to the body, headlamp must always be adjusted

after installing or after adapting.
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Main headlamps, replacing
Replacing low-beam lamp
NOTE:  Left Low Beam Headlamp M29 and Right Low Beam Headlamp M31 can be
checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical
System Control Module J519.
 Illustrations depict replacement of Low Beam Headlamp Lamp at left
Headlamp.
 Replacement of Left Low Beam Headlamp M29 and Right Low Beam
Headlamp M31 is performed analogously.
Removing:
Fig. 289: Identifying Wire Bracket & Cover Cap

 Press wire bracket - 1 - to the side in - direction of arrow - and remove cover cap - 2 -.
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Fig. 290: Separating Connector

 Separate the connector - arrow -.
Fig. 291: Compressing & Releasing Spring Clip

 Compress and release the spring clip - arrow -.

 Carefully remove Low Beam Lamp.
Installing:
NOTE:  When installing cap, ensure proper seating. Water intrusion will damage
headlamp.
 Do not touch the glass of the light bulb, when installing. Your fingers will
leave traces of grease on the glass which, when the light is switched on,
will evaporate and cloud the glass.
 Insert Low Beam Lamp so that retaining tabs lie in cut-out in reflector.
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Replacing High Beam Headlamp
NOTE:  Left High Beam Headlamp M30 and Right High Beam Headlamp M32 can
be checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical
 Illustrations depict replacement of High Beam Headlamp Lamp at left
Headlamp.
 Procedure to replace Left High Beam Headlamp M30 and Right High Beam
Headlamp M32 is the same.
Removing:
Fig. 292: Identifying Headlamp Housing Cover Cap

 Remove cover cap - arrow - at headlamp housing.
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Fig. 293: Removing/Installing Connector By Pressing Retaining Tab

 Disconnect connector - 1 - and by doing so press retaining tab in - direction of arrow -.
Fig. 294: Rotating Lamp Socket

 Turn lamp socket in - direction of arrow - and remove it from headlamp.
NOTE:  The lamp for fog light is joined permanently to lamp socket and cannot be
replaced separately.
Installing:
headlamp.
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Replacing parking light
NOTE:  Function of Left Parking Lamp M1 and Right Parking Lamp M3 can be
checked using Output Diagnostic Test Mode (DTM) of Vehicle Electrical
 Illustrations depict replacement of parking light at left headlamp.
 Replacement of Left Parking Lamp M1 and Right Parking Lamp M3 is
performed analogously.
Removing:
Fig. 295: Removing/Installing Headlamp Housing Cover Camp

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Fig. 296: Pressing Two Retaining Tabs Inward & Removing Socket With Parking Light
 Press two retaining tabs inward - arrows - and remove socket with Parking Light.
 Remove Parking Light from socket.
Installing:
headlamp.

Replacing Front Turn Signal Light
NOTE:  Left Front Turn Signal Lamp M5 and Right Front Turn Signal Lamp M7 can
 Illustrations depict replacement of Front Turn Signal Light at left
headlamp.
 Replacement of Left Front Turn Signal Lamp M5 and Right Front Turn
Signal Lamp M7 is performed analogously.
Removing:
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Fig. 298: Removing/Installing Front Turn Signal Light Harness Connectors

 Disconnect connector - arrows - at holder of Front Turn Signal Light.
Fig. 299: Turning Socket Of Front Turn Signal Light

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 Turn socket of Front Turn Signal Light in - direction of arrow -.

 Remove socket with Front Turn Signal Light from reflector.
 Press Front Turn Signal Light into socket and turn Front Turn Signal Light toward left.
 Remove Front Turn Signal Light from socket.
Installing:
headlamp.

Automatic headlamp range control adjusting motor, removing and installing
NOTE:  If adjustment motors are removed and installed or replaced, headlamp

adjustment must be checked and headlamp must be adjusted if necessary
--> 01 - MAINTENANCE .
 Illustrations depict replacement of Headlamp beam adjusting motor at left
Headlamp.
 Replacement of Left Headlamp Beam Adjustment Motor V48 and of Right
Headlamp Beam Adjustment Motor V49 is performed analogously.
Removing:
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Fig. 300: Removing Screw & Adjusting Shaft For Low & High Beam
 Remove screw - 1 - and press adjusting shaft for low beam and high beam height adjustment - 2 - in -
direction of arrow - out of guide.
 Pull adjusting shaft for low beam and high beam height adjustment - 2 - out of headlamp housing.
Fig. 301: Identifying Wire Bracket & Cover Cap

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Fig. 302: Removing/Installing Motor, Screw & Connector

 Disconnect connector - 3 -.
 Press the adjusting motor - 2 - in - direction of arrow - in order to pull out adjusting axle ball head
laterally out of ball head mount at reflector.
 Remove adjusting motor - 2 - from headlamp housing.
Installing:
headlamp.
Fig. 303: Inserting Adjusting Axle Of Adjusting Motor Carefully Into Ball Head Guide
 Insert adjusting axle of adjusting motor - 1 - carefully into ball head guide - arrow -.
Adjusting headlamps
 Adjust headlamps --> 01 - MAINTENANCE .
MAIN HEADLAMPS WITH GAS-DISCHARGE LAMPS
Main headlamps with gas-discharge lamps
CAUTION: Note usage and safety notes for gas discharge headlamps
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NOTE:  Always switch off headlamps with gas-discharge lamps and remove
ignition key before working on headlamps.
 Automatic vertical headlamp aim control of headlamps with gas-discharge
lamps has On Board Diagnostics (OBD).
Owners Manual
Main headlamps with gas-discharge lamps have "Bi-Xenon" function.
HID lamps only generate low beams in standard "Xenon" headlamps. "Bi-Xenon" allows "one" HID lamp to
generate low beams and high beams. For this purpose, an electro-mechanical adjuster (Left Headlamp Reflector
Adjustment Solenoid N395 and Right Headlamp Reflector Adjustment Solenoid N396) opens the dimmed
region of low beam Headlamp when high beam function is operated and a high beam light emission results.
For this reason, the high beam is also adjusted automatically with the low beam on "Bi-Xenon" headlamps. If
"auxiliary high beam headlamp" is installed, it can be adjusted separately.
Low beam headlamp is generated by one light source:
 Left High Intensity Gas Discharge (HID) Lamp L13 ("Bi-Xenon") and Right High Intensity Gas
Discharge (HID) Lamp L14 ("Bi-Xenon")
High beam headlamp is generated by one light source:
 Left High Intensity Gas Discharge (HID) Lamp L13 ("Bi-Xenon") and Right High Intensity Gas
Discharge (HID) Lamp L14 ("Bi-Xenon")
High beam headlamp (flasher with ignition switched off) is generated by one light source:
 Left High Beam Headlamp M30 and Right High Beam Headlamp M32 ("auxiliary high beam headlamp")
Automatic headlamp range control and vehicle electrical system control are equipped with On Board Diagnostic
(OBD) which assists troubleshooting of headlamps with gas-discharge lamps.
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Gas-discharge headlamps - assembly overview
NOTE:  After performing work which can affect headlamp adjustment, check
adjustment and correct headlamps if necessary. --> 01 - MAINTENANCE .
Fig. 304: Gas-Discharge Headlamps - Assembly Overview

1 - Wiring
 Between High intensity gas discharge lamp L13 and High intensity discharge lamp L14 and Left
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Headlamp Range Control Module J567 and Right Headlamp Range Control Module J568
2 - Left Headlamp Beam Adjustment Motor V48 and Right Headlamp Beam Adjusting Motor V49
 Removing and installing --> Automatic headlamp range control adjusting motor, removing and
installing
3 - Screws
 For Left Headlamp Beam Adjusting Motor V48 and Right Headlamp Beam Adjusting Motor V49
4 - Cover
5 - High intensity gas discharge lamp L13 and High intensity discharge lamp L14 ("Bi-Xenon")
 Type D1S, 35 W
 Replacing
 Checking
NOTE:  High intensity gas discharge lamp L13 and Left High-intensity Gas
Discharge Lamp Control Module J343 comprise one component.
 High intensity discharge lamp L14 and Right High-intensity Gas Discharge
Lamp Control Module J344 comprise one component.
6 - Left High Beam Headlamp M30 and Right High Beam Headlamp M32 ("auxiliary high beam headlamp")
 Bulb H7 12 V, 55 W
 Replacing
 Checking
7 - Cover
8 - Cover
 Lamp 12 V, W 5 W LL Xenon Blue (for RoW models)

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 Lamp 12 V, WY 5 W (for North American models, colored orange)

 Replacing
 Checking
 Lamp 12 V, PY 21 W Diadem
 Replacing
 Checking
12 - Headlamp

13 - Connection
 To Left Headlamp Beam Adjustment Motor V48 and Right Headlamp Beam Adjustment Motor V49
14 - Connection
15 - Left Headlamp Range Control Module J567 and Right Headlamp Range Control Module J568

 Coding Left Headlamp Range Control Module J567
 Coding Right Headlamp Range Control Module J568
NOTE:  If Left headlamp Range Control Module J567 and Right headlamp Range
Control Module J568 is coded, basic setting of headlamps must be
performed after the coding --> 01 - MAINTENANCE
16 - Screws
 For Left Headlamp Range Control Module J567 and Right Headlamp Range Control Module J568
17 - Adjustment bushings
18 - Screws
19 - Headlamp mount
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engine
engine
20 - Securing clip
21 - Locking bolt
23 - Screws
 For rear headlamp mount
24 - Connector
25 - Securing clip
26 - Adjusting shaft for high beam lateral adjustment
27 - Adjusting shaft for dip and high beam height adjustment
28 - Screws
 For adjusting shafts
29 - Connector
- Left Headlamp Reflector Adjustment Solenoid N395 and Right Headlamp Reflector Adjustment Solenoid N396
NOTE:  Left Headlamp Reflector Adjustment Solenoid N395 and Right Headlamp
Reflector Adjustment Solenoid N396 are located inside the headlamp and
cannot be removed or adjusted.
 Headlamp must be replaced if damaged.
 Checking
 Headlamps, removing and installing --> Headlamps, removing and installing.
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engine.
engine.
 Headlamp position, correcting --> Headlamp installation position, correcting.
Lamps of main headlamps with high-intensity gas-discharge lamps, replacing
Replacing gas-discharge lamps
NOTE:  Function of Left High Intensity Gas Discharge (HID) Lamp L13 and Right
High Intensity Gas Discharge (HID) Lamp L14 can be checked using
Vehicle Electrical System Control Module J519 Output Diagnostic Test
Mode (DTM).
 Illustrations depict replacement of gas-discharge headlamp at left
headlamp.
 Replacement of Left High Intensity Gas Discharge (HID) Lamp L13 and
Right High Intensity Gas Discharge (HID) Lamp L14 is performed
analogously.
Removing:
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Fig. 305: Pressing Wire Bracket To Side In Direction Of Arrow And Removing Cover Cap
Fig. 306: Identifying Spring Clip

 Carefully pull the gas-discharge bulb out of the socket.
Installing:
NOTE:  Do not touch the glass of the HID bulb when installing. Your fingers will
leave traces of grease on the glass which will evaporate and cloud the
glass when the bulb is switched on.
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 Do not subject the HID bulb glass to any mechanical stress. Glass cone is
extremely sensitive and is also under high pressure.
 Avoid looking directly into the light beam, since the UV rays given off by
the HID bulb are approx. 2.5 times stronger than those of a halogen bulb.
 When installing cap, ensure proper seating. Water intrusion will damage
headlamp.
 If a headlamp with automatic headlamp range control is removed,
headlamp basic setting procedure must always be performed after
installing --> 01 - MAINTENANCE .
 Insert new HID lamp so that retaining tabs lie in cut-out in reflector.
 Attach the spring clip again.
 Connect the metal connector again.
High beam headlamp bulb ("auxiliary high beam"), replacing
NOTE:  Left High Beam Headlamp M30 and Right High Beam Headlamp M32 can
 Illustrations depict replacement of High Beam Headlamp Lamp at left
Headlamp.
 Procedure to replace Left High Beam Headlamp M30 and Right High Beam
Headlamp M32 is the same.
Removing:
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Fig. 308: Separating Connector

 Separate the connector - arrow -.
Fig. 309: Identifying Headlamp Bulb Spring Clip


 Carefully remove high beam headlamp bulb.
Installing:
headlamp.
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leave traces of grease on the glass which, when the light bulb is switched
on, will evaporate and cloud the glass.
 Insert new High Beam Lamp so that retaining tabs lie in cut-out in reflector.
 Check headlamp adjustment and adjust if necessary --> 01 - MAINTENANCE
Removing:

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Fig. 311: Pressing Two Retaining Tabs Inward & Removing Socket With Parking Light
 Press two retaining tabs inward - arrows - and remove socket with Parking Light.
 Remove Parking Light from socket.
Installing:
headlamp.

headlamp.
Removing:
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Fig. 313: Removing/Installing Front Turn Signal Light Harness Connectors

 Disconnect harness connectors - arrows - at socket of Front Turn Signal Light.
Fig. 314: Turning Socket Of Front Turn Signal Light

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 Turn socket of Front Turn Signal Light in - direction of arrow -.

 Remove socket with Front Turn Signal Light from reflector.
 Press Front Turn Signal Light into socket and turn it toward left.
 Remove Front Turn Signal Light from socket.
Installing:
headlamp.

Automatic headlamp range control adjusting motor, removing and installing
NOTE:  If adjusting motors for headlamps with automatic vertical headlamp aim
control are removed and installed or replaced, basic setting of headlamps
must be performed --> 01 - MAINTENANCE .
 Illustrations depict replacement of Headlamp beam adjusting motor at left
Headlamp.
 Replacement of Left Headlamp Beam Adjustment Motor V48 and of Right
Headlamp Beam Adjustment Motor V49 is performed analogously.
Removing:
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Fig. 315: Removing Screw & Adjusting Shaft For Low & High Beam
 Remove bolt - 1 - and press adjusting shaft for low beam and high beam height adjustment - 2 - in -
direction of arrow - out of guide.
 Pull adjusting shaft for low beam and high beam height adjustment - 2 - out of headlamp housing.
Fig. 316: Pressing Wire Bracket To Side In Direction Of Arrow And Removing Cover Cap
Fig. 317: Identifying Headlamp Beam Adjustment Motor Components

 Remove mounting bolts - 1 -.
 Press headlamp beam adjustment motor - 2 - to left in order to pull ball head of adjusting shaft sideways
out of receptacle on reflector.
 Remove headlamp range control positioning motor - 2 - from headlamp housing.
Installing:
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headlamp.
 If adjusting motors for headlamps with automatic vertical headlamp aim
control are removed and installed or replaced, basic setting of headlamps
must be performed --> 01 - MAINTENANCE .
Fig. 318: Inserting Adjusting Axle Of Adjusting Motor Carefully Into Ball Head Guide
 Carefully insert positioning shaft of positioning motor - 1 - into ball head guide - arrow -.
Headlamp Reflector Adjustment Solenoid
region of low beam headlamp when high beam function is operated and a high beam light emission results.
Removing and installing Headlamp Reflector Adjustment Solenoid
Left headlamp Reflector Adjustment Solenoid N395 and Right headlamp Reflector Adjustment Solenoid N396
are located inside the headlamp and cannot be removed or adjusted separately.
Headlamp must be replaced if damaged.
Checking Headlamp Reflector Adjustment Solenoid
Left Headlamp Reflector Adjustment Solenoid N395 and Right Headlamp Reflector Adjustment Solenoid N395
can be checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module J519.
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Headlamp Range Control Module
For the Touareg, the control of the automatic or dynamic vertical headlamp aim control system occurs via two
control modules.
Control of left Headlamp is performed by Left Headlamp Range Control Module J567. Left Headlamp Range
Control Module J567 is located directly beneath left Headlamp.
Control of right Headlamp is performed by Right Headlamp Range Control Module J568. Right Headlamp
Range Control Module J568 is located directly beneath right Headlamp.
Removing and installing Headlamp Range Control Module
NOTE:  Illustrations depict replacement of Headlamp range control module at left

Headlamp.
 Replacement of Left Headlamp Range Control Module J567 and of Right
Headlamp Range Control Module J568 is performed analogously.
Removing:
Fig. 319: Identifying Lateral Adjustment Mounting Bolts

 Remove mounting bolts - arrows - of adjusting shaft for lateral adjustment.

 Remove adjusting shaft for lateral adjustment.
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Fig. 320: Identifying Headlamp Range Control Module Mounting Bolts

 Remove mounting bolts - arrows - of headlamp range control module - 1 -.

 Remove headlamp range control module - 1 - out of housing cut-out.
Fig. 321: Identifying Gas Discharge Lamp Connector And Headlamp Range Control Module Connector
 Unclip connector retaining bracket for gas-discharge lamp - 1 - in - direction of arrow - and disconnect
connector.
 Press catch of connector for headlamp range control module - 2 - in - direction of arrow - and disconnect
connector.
Installing:
NOTE:  Make sure seal has proper seating when installing headlamp range control
module. Water intrusion will damage headlamp.
 After installing a new control module, it must be coded:
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Coding Left Headlamp Range Control Module J567.
Coding Right Headlamp Range Control Module J568.

Left Headlamp Range Control Module J567 , coding
Fault Finding".
sequence:
 Body
 Automatic vertical headlamp aim control
 Automatic headlamp range control functions

 Coding Control Module for Left Light Control
NOTE:  If Left Headlamp Range Control Module J567 is coded, basic setting of
Headlamps must be performed after coding --> 01 - MAINTENANCE .
Right Headlamp Range Control Module J568 , coding
Fault Finding".
sequence:
 Body
 Automatic vertical headlamp aim control

 Coding Control Module for Right Light Control
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NOTE:  If Right Headlamp Range Control Module J568 is coded, basic setting of
Headlamps must be performed after coding --> 01 - MAINTENANCE .
Level control system sensor
Vehicles without level control system (air spring shock absorber)
A vehicle level sensor is located at front axle (Left Front Level Control System Sensor G78) and (Left Rear
Level Control System Sensor G76) is located at rear axle.
The vehicle level sensors are a component of automatic headlamp range control.
The vehicle level sensors transmit vehicle level in the form of a PWM signal (pulse-width modulated signal) to
the Left Headlamp Range Control Module J567 and to the Right Headlamp Range Control Module J568.
In order to generate this PWM signal, voltage is supplied to Left Rear Level Control System Sensor G76 via
two plus wires and one Ground (GND) wire. Voltage is supplied to Left Front Level Control System Sensor
G78 via one plus-wire and two Ground (GND) wires.
Removing and installing Level Control System Sensor :
Removing and installing Left Front Level Control System Sensor G78 --> 40 - FRONT SUSPENSION .
Removing and installing Left Rear Level Control System Sensor G76 --> 42 - REAR SUSPENSION .
NOTE:  If the vehicle Level sensors are replaced, headlamp basic setting must be
performed --> 01 - MAINTENANCE .
Vehicles with level control system (air spring shock absorber)
There are two each Vehicle Level Sensors located at front axle (Left Front Level Control System Sensor G78
and Right Front Level Control Sensor G289) and at rear axle (Left Rear Level Control System Sensor G76 and
Right Rear Level Control System Sensor G77).
The level control system sensors are a component of vehicle level control system.
The level control system sensors transmit vehicle level in the form of a signal to the Level Control System
Control Module J197.
Level Control System Control Module J197 transmits this signal to Left Headlamp Range Control Module J567
and to Right Headlamp Range Control Module J568.
Removing and installing Left Front Level Control System Sensor G78 and Right Front Level Control Sensor
G289 --> 40 - FRONT SUSPENSION .
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Removing and installing Left Rear Level Control System Sensor G76 and Right Rear Level Control System
Sensor G77 --> 42 - REAR SUSPENSION .
Adjusting headlamps
 Adjusting headlamp with HID bulbs --> 01 - MAINTENANCE .
Notes on application and safety instructions for gas discharge lamps
CAUTION:  Never replace lamps when you are not familiar with the
corresponding actions, safety precautions and tools.
 If repair work is performed on main headlamp with gas discharge lamps, note the following:
 Notes on hazardous high voltage/currents Notes on hazardous high voltage/currents

 Notes on pressure, temperature and radiation/electric arc Notes on pressure, temperature and
radiation/glare
 Assembly notes for gas discharge lamps Assembly notes on gas discharge lamps
 Disposal regulations for gas discharge lamps Disposal regulations for gas discharge lamps
 Protective eyewear
 Gloves
Notes on hazardous high voltage/currents
CAUTION: Control modules of lighting system, connectors or components in area of

lamp socket carry hazardous high voltage.
Operating the control module and igniter is only permissible with lamp.
CAUTION:  Switch off ignition, switch off all electrical components and remove
ignition key.
 Make sure all components have zero potential when working on
headlamp system, even residual voltage after switching off
headlamps must be discharged.
 Residual voltages are discharged by switching low beam on and off
again after ignition key was removed.
 Make sure lamps cannot be switched on when working on headlamp
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system.
Notes on pressure, temperature and radiation/glare
CAUTION:  Lamp must only be operated in headlamp housing (protection

against contact because of hot lamp, absorption of ultraviolet
radiation, avoiding danger of glare, explosion protection).
 Glass cones of bulbs can become very hot - danger of burns!
 Avoid looking directly into light beam, since UV radiation of gas
discharge lamp is approx. 2.5 times higher than that of standard
Halogen lamps.
 Avoid looking into light beam (danger of glare); vision can be
impaired for a longer period of time.
CAUTION:  Avoid contact with burst glass cone.

 H7 bulbs and gas discharge lamps (Xenon/Bi-Xenon) are under
pressure and can burst when replaced - danger of injury!
 When removing and installing HID bulbs, always wear safety glasses
and gloves.
Assembly notes on gas discharge lamps
CAUTION:  Before replacing a bulb, the corresponding consumer must always

be switched off.
 Switch off ignition, switch off all electrical components and remove
ignition key.
 Do not touch glass cone of bulb with bare fingers, use clean cloth
gloves. The remaining fingerprint would evaporate due to the heat of
the operated bulb and would condense on the reflector which would
impair headlamp luminosity.
 A bulb must only be replaced with one of the same version. Bulb
identification can be found on bulb socket or glass cone.
 Harness connectors must engage correctly when installed and must

be checked for proper connection.
Disposal regulations for gas discharge lamps
CAUTION:  Gas discharge lamps must be disposed of as hazardous waste, never

dispose of gas discharge lamps via domestic waste.
 Gas discharge lamps contain metallic mercury (Hg) and traces of
thallium, they must not be destroyed.
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 These components must be returned for proper recycling in

accordance with national legislation.
 Dispose of only in the designated containers at the responsible
collection point.
MAIN HEADLAMPS WITH GAS DISCHARGE LAMPS AND CORNERING LIGHT, THROUGH
11/06
Main headlamps with gas discharge lamps and cornering light, through 11/06
CAUTION: Note usage and safety notes for gas discharge headlamps --> Notes on
application and safety instructions for gas discharge lamps
NOTE:  Before working on HID headlamps and cornering lamps, always switch off
headlamps and remove ignition key.
 Automatic headlamp range control of HID headlamps with cornering lamps
has On Board Diagnostics (OBD).
Owners Manual
Main headlamps with gas-discharge lamps and cornering lamps (AFS = Adaptive Front lighting System) have
"Bi-Xenon" function.
For this reason, the high beam is also adjusted automatically with the low beam on "Bi-Xenon" headlamps.
Main headlamps with HID lamps and cornering lamps are not equipped with "auxiliary high beams".
Cornering lamps system performs the following functions:
 Swiveling low beam and high beam (dynamic cornering lamp) from vehicles speeds above 10 kmh and
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steering wheel angle.

 Cornering lamp (static cornering lamp) at sharp curves (curve radius 500 m) or on turning-off and
vehicles speeds below 50 kmh
Automatic headlamp range control, cornering lamps and vehicle electrical system control are equipped with On
Board Diagnostic (OBD) which assists troubleshooting of main headlamps with HID lamps and cornering
lamps.
Main headlamps with HID lamps and cornering lamps, assembly overview
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Fig. 322: Main Headlamps With HID Lamps And Cornering Lamps, Assembly Overview
1 - Adjusting shaft for low beam and high beam height adjustment
2 - Connector
3 - Screws
4 - Left High-intensity Gas Discharge Lamp Control Module J343 and Right High-intensity Gas Discharge
Lamp Control Module J344
NOTE:  Left High-intensity Gas Discharge Lamp Control Module J343 and Right
High-intensity Gas Discharge Lamp Control Module J344 is not capable of
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On Board Diagnostic (OBD).

 Removing and installing --> High-intensity Gas Discharge Lamp Control
Module, removing and installing
5 - Screws
6 - Bracket
7 - Cable ties
8 - Left Cornering Lamp L148 or Right Cornering Lamp L149
 Bulb H7 12 V, 55 W
 Replacing
 Checking
9 - Cover
10 - Headlamp Range/Cornering Lamp Control Module J745
 Component location: at center under instrument panel

 Coding
 Output Diagnostic Test Mode (DTM)
 Adapting
NOTE:  If Headlamp Range/Cornering Lamp Control Module J745 is coded,

headlamp basic setting must then be performed --> 01 - MAINTENANCE .
 Type D1S, 35 W
 Replacing
 Checking
12 - Wiring
 Between Left High Intensity Gas Discharge (HID) Lamp L13 or Right High Intensity Gas Discharge
(HID) Lamp L14 and Left High-intensity Gas Discharge Lamp Control Module J343 or Right High-
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intensity Gas Discharge Lamp Control Module J344
 Lamp 12 V, W 5 W
 Replacing
 Checking
14 - Headlamp

15 - Left Headlamp Power Output Stage J667 or Right Headlamp Power Output Stage J668
NOTE:  After installing a new headlamp power output stage, Headlamp

Range/Cornering Lamp Control Module J745 must be coded and then
basic setting of headlamps must be performed --> 01 - MAINTENANCE .
16 - Screws
 For mounting left/right headlamp power output stage to headlamp
17 - Adjustment bushings
18 - Screws
19 - Headlamp mount
engine
engine
20 - Securing clip
21 - Locking bolt
Microsoft
 For mounting bolts of rear headlamp mount
23 - Screws
24 - Connector
25 - Securing clip
 Lamp 12 V, PY 21 W
 Replacing
 Checking
27 - Cover
28 - Lamp socket with grip piece and harness connector
29 - Screws
- Left Headlamp Reflector Adjustment Solenoid N395 and Right Headlamp Reflector Adjustment Solenoid
N396
 Headlamp must be replaced if damaged --> Headlamps, removing and
installing.
 Checking
- Left Swivel Module Position Sensor G474 or Right Swivel Module Position Sensor G475
NOTE:  Left Swivel Module Position Sensor G474 and Right Swivel Module
Position Sensor G475 are located inside the headlamp and cannot be
replaced or adjusted separately.
installing.
- Left Headlamp Beam Adjustment Motor V48 and Right Headlamp Beam Adjusting Motor V49
Microsoft
NOTE:  Left Headlamp Beam Adjustment Motor V48 and Right Headlamp Beam
Adjustment Motor V49 is located inside the headlamp and must not be
replaced.
installing.
 Checking
- Left Dynamic Cornering Light Motor V318 or Right Dynamic Cornering Light Motor V319
NOTE:  Left Dynamic Cornering Light Motor V318 and Right Dynamic Cornering
Light Motor V319 is located inside the headlamp and must not be replaced.
installing.
 Checking
 Headlamps, removing and installing --> Headlamps, removing and installing.
engine.
engine.
Lamps of main headlamps with high-intensity gas-discharge lamps and cornering lamps, replacing
Microsoft

Mode (DTM).
headlamp.
analogously.
Removing:
Fig. 323: Removing/Installing Mounting Bolts & Pulling Off Bracket With Hid Lamp Control Module
 Remove mounting bolts - arrows - and pull off bracket - 1 - with HID lamp control module - 2 - as far as
wire lengths allow from headlamp.
NOTE:  HID lamp control module - 2 - must not be removed from bracket - 1 -.
Fig. 324: Removing/Installing Retaining Tab & Harness Connector

Microsoft
 Disengage retaining tab - arrow A - of harness connector - 1 - and disconnect harness connector - 1 -.
NOTE:  Harness connector - 2 - of HID lamp control module must not be

disengaged and disconnected.
Fig. 325: Identifying HID Lamp & Harness Connector

 Disconnect harness connector - 2 - from HID lamp - 1 -.
 Remove bracket - 1 - with HID lamp control module and wire from headlamp.
Microsoft
Fig. 327: Identifying Wire Clamp & Gas-Discharge Lamp

 Release wire clamp - 1 - and fold it to the side.

 Carefully remove gas-discharge lamp - 2 - from mount.
Installing:
 Avoid looking directly into focused light beam.
 Make sure seal has proper seating when installing bracket with High-
intensity Gas Discharge Lamp Control Module. Water intrusion will
damage headlamp.
Microsoft

Removing:
NOTE:  HID lamp control module - 2 - must not be removed from bracket - 1 -.

Microsoft
NOTE:  Harness connector - 2 - of HID lamp control module must not be

disengaged and disconnected.

Microsoft
Fig. 332: Removing/Installing Lamp Socket

 Disengage - arrows - lamp socket - 1 - with parking lamp.

 Pull lamp socket - 1 - as far out of reflector - 2 - as wire lengths allow.
Fig. 333: Parking Light And Lamp Socket

 Remove parking light - 2 - from lamp socket - 1 - in - direction of arrow -.
Installing:
NOTE:  Make sure seal has proper seating when installing bracket with High-
intensity Gas Discharge Lamp Control Module. Water intrusion will
damage headlamp.
Microsoft

headlamp.
Removing:

 Pull off cover cap - 1 - on inside of headlamp housing.
Microsoft
Fig. 335: Identifying Harness Connector

 Disconnect harness connector - 1 -.
Fig. 336: Turning Front Turn Signal Light Socket

 Turn socket - 1 - with Front Turn Signal Light in - direction of arrow -.

 Remove socket - 1 - with Front Turn Signal Light from reflector.
Fig. 337: Removing/Installing Front Turn Signal Light Bulb

Microsoft
 Push front turn signal light - 2 - into socket - 1 - and rotate front turn signal light - 2 - in - direction of
arrow -.
 Remove Front Turn Signal Light - 2 - from socket - 1 -.
Installing:
headlamp.

Replacing cornering lamps (turn-off lamp, static cornering lamp)
NOTE:  Left Cornering Lamp L148 and Right Cornering Lamp L149 can be checked
via output Diagnostic Test Mode (DTM) of Headlamp Range/Cornering
Lamp Control Module J745.
 Illustrations depict replacement of cornering lamp at right headlamp.
 Replacement of Left Cornering Lamp L148 and Right Cornering Lamp L149
is performed analogously.
Removing:
Microsoft

 Pull off cover cap - 1 - on top of headlamp housing.
Fig. 339: Removing/Installing Cornering Lamp

NOTE:  Cornering lamp - 2 - is clipped into the reflector - 1 -.

 When removing cornering lamp, the harness connector - 3 - is not
disconnected first.
 Push harness connector and thereby the lamp socket downward until the lamp can be felt as loose.
 Pull cornering lamp out of reflector by grasping on the harness connector - 3 -.
 Guide cornering lamp with harness connector connected out of headlamp housing in - direction of arrow
-.
Fig. 340: Identifying Cornering Lamp Harness Connector

 Disconnect harness connector - 2 - of cornering lamp - 1 -.
Microsoft
Installing:
headlamp.
Fig. 341: Identifying Cornering Lamp Harness Connector

 Connect harness connector - 2 - of cornering lamp - 1 -.

 Guide cornering lamp with harness connector connected into headlamp housing.
Fig. 342: Pushing Cornering Lamp Into Reflector

 Push cornering lamp into reflector in - direction of arrow - as depicted in the illustration.
NOTE:  Cornering lamp must engage audibly.

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Automatic Headlamp Range Control Adjusting Motor
Left Headlamp Beam Adjustment Motor V48 and Right Headlamp Beam Adjustment Motor V49 is located
inside the headlamp and cannot be disassembled.
Headlamp must be replaced if damaged --> Headlamps, removing and installing.
Checking headlamp range control adjusting motor
Left Headlamp Beam Adjustment Motor V48 and Right Headlamp Beam Adjustment Motor V49 can be
checked via output Diagnostic Test Mode (DTM) of Headlamp Range/Cornering Lamp Control Module J745.
Dynamic cornering lamp adjusting motor
Left Dynamic Cornering Light Motor V318 and Right Dynamic Cornering Light Motor V319 is located inside
the headlamp and cannot be disassembled.
Checking dynamic cornering lamp adjusting motor
Left Dynamic Cornering Light Motor V318 and Right Dynamic Cornering Light Motor V319 can be checked
via output Diagnostic Test Mode (DTM) of Headlamp Range/Cornering Lamp Control Module J745.
Swivel Module Position Sensor
Left Swivel Module Position Sensor G474 and Right Swivel Module Position Sensor G475 are located inside
the headlamp and cannot be replaced or adjusted separately.
are located inside the headlamp and cannot be replaced or adjusted separately.
Headlamp must be replaced if damaged.

Microsoft
Headlamp power output stage
Headlamp power output stage, removing and installing
NOTE:  Illustrations depict replacement of headlamp power output stage at left

headlamp.
 Replacement of Left Headlamp Power Output Stage J667 and of Right
Headlamp Power Output Stage J668 is similar.
Removing:
Fig. 343: Identifying Adjusting Shaft

 Remove mounting bolts - arrows - and remove adjusting shaft - 1 - for low beam and high beam height
adjustment from headlamp.
Microsoft
Fig. 344: Removing/Installing Headlamp Power Output Stage

 Remove mounting bolts - arrows - and pull headlamp power output stage - 1 - as far from headlamp as
wire lengths allow.
Fig. 345: Disengaging/Engaging Headlamp Power Output State Harness Connectors

 Disengage harness connectors - arrows - and disconnect them.

 Remove headlamp power output stage from headlamp.
Installing:
NOTE:  Make sure seals are fitted correctly when installing covers and installing
headlamp power output stage. Water intrusion will damage headlamp.
 After installing a new headlamp power output stage, Headlamp
Microsoft

Coding headlamp power output stage

basic setting of headlamps must be performed.
 Code Headlamp Range/Cornering Lamp Control Module J745.

 Perform basic setting of headlamps --> 01 - MAINTENANCE .
High-intensity Gas Discharge Lamp Control Module, removing and installing
 Illustrations depict replacement of High-intensity Gas Discharge Lamp
Control Module at left headlamp.
 Replacement of Left High-intensity Gas Discharge Lamp Control Module
J343 and of Right High-intensity Gas Discharge Lamp Control Module J344
Removing:
Microsoft
NOTE:  High-intensity Gas Discharge Lamp Control Module - 2 - is not yet

removed from bracket - 1 - to obtain better access to the harness
connectors.

 Disengage retaining bracket - 3 - for harness connector - 2 - in - direction of arrow B - and disconnect
harness connector - 2 -.

Microsoft
Fig. 350: Identifying Lamp Control Module & Bracket

 Unscrew mounting bolts - arrows - and remove High-intensity Gas Discharge Lamp Control Module - 1 -
from bracket - 2 -.
Installing:
NOTE:  Make sure seals are fitted correctly when installing bracket and installing
High-intensity Gas Discharge Lamp Control Module. Water intrusion will
damage headlamp.

Headlamp Range/Cornering Lamp Control Module J745

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Removing and installing Headlamp Range/Cornering Lamp Control Module J745
Fig. 351: Release Lever T10039


 Wedge T10039/1
Removing:
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Fig. 352: Identifying Radio, Cover, Radio/Navigation System, A/C Control Head
 In vehicles without radio/navigation system or without radio, pry cover - 1 - out of mounts using trim
removal wedge T10039/1.
 If necessary, remove radio - 2 - --> 91 RADIO, TELEPHONE, NAVIGATION, TRIP COMPUTER .
 If necessary, remove radio/navigation system - 3 - --> 91 RADIO, TELEPHONE, NAVIGATION,
TRIP COMPUTER .
 Remove all switches in instrument panel center --> Switch in center of instrument panel, removing
and installing.
 Remove A/C control head - 4 - --> 87 AIR CONDITIONING .

 Remove side instrument cluster cover on front passengers side --> 68 - INTERIOR EQUIPMENT .
 Remove cover in footwell on drivers side --> 68 - INTERIOR EQUIPMENT .
Fig. 353: Identifying Decorative Strip, Panel, Clamping Washer, Washer, Threaded Pin & Wing
NOTE:  Two versions of panel - 2 - are installed in the Touareg, a panel with
threaded pin - 3 - and clamping washer - 4 - or a panel without threaded
pin and clamping washer.
 Clamping washer - 4 - is depicted as partially removed in the illustration
for a better overview. While installed, clamping washer is accessible
through radio system cut-out, however it is not visible.
 Clamping washer - 4 - is destroyed upon removal and must be replaced
during installation.
Microsoft
 Using a small screwdriver through the radio system cut-out, pry up wing - 5 - of clamping washer - 4 -
and pull off clamping washer - 4 - from threaded pin - 3 -.
 Pry panel - 2 - out of mounts using trim removal wedge T10039/1 and unclip adjustment wheel housing -
1 - from panel.
 In vehicles with adjustment wheel housing light, disconnect harness connector from adjustment wheel
housing - 1 - and remove adjustment wheel housing - 1 -.
 Pry decorative strip - 6 - out of mounts using wedge T10039/1.
Fig. 354: Removing/Installing Bracket Mounting Bolts

 Remove mounting bolts - 1 - and remove bracket - 2 - from instrument panel.
Fig. 355: Identifying Glove Compartment Lining Mat

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 Open glove compartment and remove lining mat - 1 - from glove compartment.
 Remove Glove Compartment Light W6 --> Glove Compartment Light W6 , removing and installing.
Fig. 356: Remove/Install Lower Instrument Panel & Mounting Bolts Component
 Route all wiring harnesses which lead inward through lower section of instrument panel - 2 - so as to be
able to remove lower section of instrument panel - 2 -.
 Remove mounting bolts - 1 - (13 mounting bolts total) and remove lower section of instrument panel - 2 -
from instrument panel.
Fig. 357: Identifying Range/Cornering Lamp Control Module Harness Connector

 Disengage harness connector - 2 - and disconnect harness connector - 2 - from Headlamp

Range/Cornering Lamp Control Module J745 - 1 -.
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Fig. 358: Removing/Installing Range/Cornering Lamp Control Module Bracket & Bolts
 Remove mounting bolts - 1 - and remove bracket - 2 - with Headlamp Range/Cornering Lamp Control
Module J745 in - direction of arrow -.
Fig. 359: Identifying Range/Cornering Lamp Control Module & Bracket

 Clip retaining hooks inward - arrows - and remove Headlamp Range/Cornering Lamp Control Module
J745 - 2 - from bracket - 1 -.
Installing:
Microsoft
NOTE:  Before installing, check whether a securing clip is installed in center of

panel - 2 - as in the area of the threaded pin - 3 -. If this is not the case, a
securing clip must be installed at this location.
 If a panel without threaded pin and clamping washer was installed in the
vehicle and the panel is replaced by a version with threaded pin and
clamping washer, the securing clip in the area of the threaded pin must
then be removed before the installation.
 Use a new clamping washer - 4 - for the installation.
 After installing panel - 2 - , the new clamping washer - 4 - must be inserted
to stop (do not turn!) in the depicted position.
Fig. 361: Identifying Center Console Bolts & Brackets

Microsoft
 Tighten mounting bolts for bracket - 7 - in the following sequence.
 Mounting bolt 1
 Mounting bolt 6
 Mounting bolt 3
 Mounting bolt 4
 Mounting bolt 2
 Mounting bolt 5
NOTE:  After installing a new Headlamp Range/Cornering Lamp Control Module,

control module must be coded and then basic setting of headlamps must
be performed --> 01 - MAINTENANCE .

Coding Headlamp Range/Cornering Lamp Control Module J745
Fault Finding".
sequence:
 Body
 Automatic Headlamp Range/Cornering Lamp Control

 Code Control Module for AFS Light Control
NOTE:  If Headlamp Range/Cornering Lamp Control Module J745 is coded, basic

setting of headlamps must be performed after coding --> 01 -
MAINTENANCE .
Output Diagnostic Test Mode (DTM) of Headlamp Range/Cornering Lamp Control Module J745
The following components and functions can be checked via output Diagnostic Test Mode (DTM) of Comfort
System Central Control Module J393 :
Microsoft
 Left Headlamp Beam Adjustment Motor V48 and Right Headlamp Beam Adjusting Motor V49
 Left Dynamic Cornering Light Motor V318 or Right Dynamic Cornering Light Motor V319
 Left Cornering Lamp L148 or Right Cornering Lamp L149
Fault Finding".
sequence:
 Body

 Output Diagnostic Test Mode (DTM) of AFS
Adapting Headlamp Range/Cornering Lamp Control Module J745
The "Adapt Headlamp Range/Cornering Lamp Control Module" function was not yet implemented at time of
publication.
The Vehicle Level Sensors are a component of automatic headlamp range control.
The Vehicle Level Sensors transmit vehicle level in the form of a PWM signal (pulse-width modulated signal)
to the Headlamp Range/Cornering Lamp Control Module J745.
two plus-wires and one Ground (GND) wire. Voltage is supplied to Left Front Level Control System Sensor
Removing and installing Left Front Level Control System Sensor G78 --> 40 - FRONT SUSPENSION .
Removing and installing Left Rear Level Control System Sensor G76 --> 42 - REAR SUSPENSION .
Microsoft
Level Control System Control Module J197 transmits this signal to the Headlamp Range/Cornering Lamp
Removing and installing Left Front Level Control System Sensor G78 and Right Front Level Control Sensor
G289 --> 40 - FRONT SUSPENSION .
Removing and installing Left Rear Level Control System Sensor G76 and Right Rear Level Control System
Sensor G77 --> 42 - REAR SUSPENSION .
Adjusting headlamps
 Notes on hazardous high voltage/currents --> Information on dangerous high voltage/current

 Notes on pressure, temperature and radiation/electric arc --> Notes on pressure, temperature and
radiation/glare
 Assembly notes for gas discharge lamps --> Assembly notes on gas discharge lamps
 Disposal regulations for gas discharge lamps --> Disposal regulations for gas discharge lamps
Microsoft
 Gloves
Information on dangerous high voltage/current

ignition key.
system.

Halogen lamps.

and gloves.
Microsoft

be switched off.
ignition key.


collection point.
MAIN HEADLAMPS WITH GAS DISCHARGE LAMPS AND CORNERING LIGHT, FROM 12/06
General information
NOTE:  Before working on HID headlamps and cornering lamps, always switch off
headlamps and remove ignition key.
 Automatic headlamp range control of HID headlamps with cornering lamps
has On Board Diagnostics (OBD).
Owners Manual
Microsoft
Main headlamps with gas-discharge lamps and cornering lamps (AFS = Adaptive Front lighting System) have
"Bi-Xenon" function.
For this reason, the high beam is also adjusted automatically with the low beam on "Bi-Xenon" headlamps.
Main headlamps with HID lamps and cornering lamps are not equipped with "auxiliary high beams".
Cornering lamps system performs the following functions:
 Swiveling low beam and high beam (dynamic cornering lamp) from vehicles speeds above 10 kmh and
steering wheel angle.
 Cornering lamp (static cornering lamp) at sharp curves (curve radius 500 m) or on turning-off and
vehicles speeds below 50 kmh
Automatic headlamp range control, cornering lamps and vehicle electrical system control are equipped with On
Board Diagnostic (OBD) which assists troubleshooting of main headlamps with HID lamps and cornering
lamps.
NOTE:  Malfunction of the range control or AFS system are displayed in the
instrument cluster with the "lamp failure" indicator lamp.
Main headlamps with HID lamps and cornering lamps, assembly overview
Microsoft
Fig. 362: Main Headlamps With Hid Lamps And Cornering Lamps, Assembly Overview
1 - Screws
2 - Left High-intensity Gas Discharge Lamp Control Module J343 and Right High-intensity Gas Discharge
Lamp Control Module J344
 Removing and installing --> Gas discharge lamp control module
3 - Bolt
4 - Left Headlamp Power Output Stage J667 or Right Headlamp Power Output Stage J668
Microsoft

5 - Left Cornering Lamp L148 or Right Cornering Lamp L149
 Bulb H7 12 V, 55 W
 Replacing
 Checking
 Lamp 12 V, PY 21 W
 Replacing
 Checking
8 - Cover
9 - Cover
application and safety instructions for gas discharge lamps.
 Type D1S, 35 W
 Replacing
 Checking
 Lamp 12 V, W 5 W
 Replacing
 Checking
12 - Headlamp
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13 - Screws
 5 Nm
14 - Headlamp mount
 Removing and installing --> Headlamp mount, removing and installing
15 - Headlamp Range/Cornering Lamp Control Module J745
 Component location: at center under instrument panel

 Coding
NOTE:  If Headlamp Range/Cornering Lamp Control Module J745 is coded,

headlamp basic setting must then be performed --> 01 - MAINTENANCE .
- Left Headlamp Reflector Adjustment Solenoid N395 and Right Headlamp Reflector Adjustment Solenoid N396
installing.
 Checking
- Left Swivel Module Position Sensor G474 or Right Swivel Module Position Sensor G475
NOTE:  Left Swivel Module Position Sensor G474 and Right Swivel Module
Position Sensor G475 are located inside the headlamp and cannot be
replaced or adjusted separately.
installing.
 Checking
- Left Headlamp Beam Adjustment Motor V48 and Right Headlamp Beam Adjusting Motor V49
Microsoft
NOTE:  Left Headlamp Beam Adjustment Motor V48 and Right Headlamp Beam
Adjustment Motor V49 is located inside the headlamp and must not be
replaced.
installing.
 Checking
- Left Dynamic Cornering Light Motor V318 or Right Dynamic Cornering Light Motor V319
NOTE:  Left Dynamic Cornering Light Motor V318 and Right Dynamic Cornering
Light Motor V319 is located inside the headlamp and must not be replaced.
installing.
 Checking
NOTE:  It is not necessary to disconnect battery.

 Illustrations depict removal and installation of left headlamp.
Removing:

 Disengage and disconnect harness connector - 1 -.
Microsoft
Fig. 364: Identifying Tip Locking Lever

 Tip locking lever - 1 - in direction of arrow.
Fig. 365: Identifying Tip Headlamp

 To tip headlamp - 1 - , press inward in - direction of arrow - with balls of hands in rear area.
Fig. 366: Removing/Installing Headlamp

Microsoft
 Remove headlamp in - direction of arrow - straight forward and out of body opening.
Installing:

NOTE:  The illustration shows the removal of the left headlamp mount. The
removal of the right headlamp mount is done in the same way.
Removing:
 Remove front bumper cover: Bumper cover, > 10.2006, --> 63 - BUMPERS or Bumper cover, 11.2006 >
--> 63 - BUMPERS .
 Remove bumper lower assembly component guide profile --> 63 - BUMPERS
NOTE:  For overview purposes, the headlamp mount is shown removed.
Fig. 367: Identifying Mount & Mounting Bolts

 Remove four mounting bolts and remove mount - 1 - forward out of body opening.
Microsoft
Installing:

installation.
Lamps of main headlamps with high-intensity gas-discharge lamps and cornering lamps, replacing
Mode (DTM).
headlamp.
analogously.
Removing:
Microsoft
Fig. 368: Identifying Cover Cap

 Remove cover cap - 1 - from back side of headlamp housing.
Fig. 369: Identifying Connector Harness

CAUTION:  There are pressures from 7 bar (cold) to 100 bar (hot) in the glass
portion of the HID bulb. The hot glass of the bulb can reach
temperatures of up to 700 degrees Celsius.
 The glass can explode and there is a danger of burning.
and gloves.
Microsoft
Fig. 370: Removing/Installing Gas Discharge Lamp

 Remove gas discharge lamp - 1 - in - direction of arrow - and carefully remove it toward rear from
headlamp.
Installing:
 Avoid looking directly into focused light beam.
 When installing cover cap, check cover cap for proper seating. Water
intrusion will damage headlamp.
Microsoft

Removing:

 Remove cover cap - 1 - from back side of headlamp housing.
Fig. 372: Removing/Installing Bulb Socket

 Remove bulb socket - 1 - back from reflector while being careful of connecting wires.
Microsoft
Fig. 373: Parking Light And Lamp Socket

 Remove parking light bulb - 2 - in - direction of arrow - from bulb socket - 1 -.
Installing:
NOTE:  Ensure parking light bulb socket is seated correctly in reflector.

 When installing cover cap, check cover cap for proper seating. Water

headlamp.
Removing:
Microsoft
Fig. 374: Identifying Headlamp Housing Top Cover Cap

 Remove cover cap - 1 - on top of headlamp housing.

 Disconnect harness connector - 1 -.
Microsoft
Fig. 376: Identifying Grip Piece

 Press grip piece - 1 - in direction of reflector and rotate it in - direction of arrow - with front turn signal
lamp.
 Remove grip piece - 1 - with Front Turn Signal Light from reflector.
Fig. 377: Pushing Front Turn Signal Light Into Grip Piece & Rotating Front Turn Signal Light In
Direction Of Arrow
 Push front turn signal light - 2 - into grip piece - 1 - and rotate front turn signal light - 2 - in - direction of
arrow -.
 Remove Front Turn Signal Light - 2 - from grip piece - 1 -.
Installing:
headlamp.

Replacing cornering lamps (turn-off lamp, static cornering lamp)
NOTE:  Left Cornering Lamp L148 and Right Cornering Lamp L149 can be checked
via output Diagnostic Test Mode (DTM) of Headlamp Range/Cornering
Lamp Control Module J745.
Microsoft
 The following illustrations depict replacement of left cornering lamp.

 Replacement of Left Cornering Lamp L148 and Right Cornering Lamp L149
Removing:
Fig. 378: Removing/Installing AFS Power Output Module Carrier Plate

 Release AFS power output module carrier plate - 1 - by pressing on both buttons - A arrows -.
 Tip carrier plate with AFS power output module in upward - direction of arrow B - and remove it from
headlamp housing.
Fig. 379: Rotating Cornering Lamp With Connected Connector In Direction Of Arrow & Carefully
Remove It Back From Headlamp Housing
 Rotate cornering lamp - 1 - with connected connector in - direction of arrow - and carefully remove it
back from headlamp housing.
Microsoft
Fig. 380: Identifying Connector & Cornering Lamp

 Disconnect connector - 1 - from cornering lamp - 1 -.
Installing:
NOTE:  When installing carrier plate with AFS power output module, ensure
locking mechanisms are seated correctly and close completely. Water

Automatic Headlamp Range Control Adjusting Motor
Left Headlamp Beam Adjustment Motor V48 and Right Headlamp Beam Adjustment Motor V49 is located
inside the headlamp and cannot be disassembled.
Checking headlamp range control adjusting motor
Left Headlamp Beam Adjustment Motor V48 and Right Headlamp Beam Adjustment Motor V49 can be
checked via output Diagnostic Test Mode (DTM) of Headlamp Range/Cornering Lamp Control Module J745.
Dynamic cornering lamp adjusting motor
Left Dynamic Cornering Light Motor V318 and Right Dynamic Cornering Light Motor V319 is located inside
Microsoft
the headlamp and cannot be disassembled.
Checking dynamic cornering lamp adjusting motor
Left Dynamic Cornering Light Motor V318 and Right Dynamic Cornering Light Motor V319 can be checked
via output Diagnostic Test Mode (DTM) of Headlamp Range/Cornering Lamp Control Module J745.
Swivel Module Position Sensor
Left Swivel Module Position Sensor G474 and Right Swivel Module Position Sensor G475 are located inside
the headlamp and cannot be replaced or adjusted separately.
Swivel Module Position Sensor, checking
Fault Finding".
sequence:
 Body
 Automatic headlamp range control electrical components

 Swivel Module Position Sensor
are located inside the headlamp and cannot be replaced or adjusted separately.

Microsoft
Headlamp power output stage
Headlamp power output stage, removing and installing
NOTE:  Illustrations depict replacement of headlamp power output stage at left

headlamp.
 Replacement of Left Headlamp Power Output Stage J667 and of Right
Headlamp Power Output Stage J668 is performed analogously.
Removing:
Fig. 381: Identifying Headlamp Power Output Module

 Remove three mounting bolts - arrows - and remove headlamp power output module - 1 - straight out of
headlamp housing.
NOTE:  The headlamp power output module electrical connector is disconnected

at the same time it is removed from the headlamps housing.
Installing:
NOTE:  When installing the headlamp power output module, ensure seals are
Microsoft
seated properly. Water intrusion will damage headlamp.

 After installing a new headlamp power output stage, Headlamp

New headlamp power output module

basic setting of headlamps must be performed.
 Code Headlamp Range/Cornering Lamp Control Module J745.

 Perform basic setting of headlamps --> 01 - MAINTENANCE .
Gas discharge lamp control module
High-intensity Gas Discharge Lamp Control Module, removing and installing
 Illustrations depict replacement of High-intensity Gas Discharge Lamp
Control Module at left headlamp.
 Replacement of Left High-intensity Gas Discharge Lamp Control Module
J343 and of Right High-intensity Gas Discharge Lamp Control Module J344
Removing:
Microsoft
Fig. 382: Removing/Installing HID Headlamp Control Module & Mounting Bolts
 Remove both mounting bolts - arrows - and remove HID headlamp control module - 1 - straight out of
headlamp housing.
NOTE:  The HID headlamp control module electrical connector is disconnected at

the same time it is removed from the headlamps housing.
Installing:
NOTE:  Make sure seals have proper seating when installing High-intensity Gas
Discharge Lamp Control Module. Water intrusion will damage headlamp.

Headlamp Range/Cornering Lamp Control Module J745
Removing and installing Headlamp Range/Cornering Lamp Control Module J745
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Fig. 383: Release Lever T10039 & Wedge T10039/1


 Wedge T10039/1
Removing:
Fig. 384: Identifying Radio, Cover, Radio/Navigation System, A/C Control Head
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 In vehicles without radio/navigation system or without radio, pry cover - 1 - out of mounts using trim
removal wedge T10039/1.
 If necessary, remove radio - 2 - --> 91 RADIO, TELEPHONE, NAVIGATION, TRIP COMPUTER .
 If necessary, remove radio/navigation system - 3 - --> 91 RADIO, TELEPHONE, NAVIGATION,
TRIP COMPUTER .
 Remove all switches in instrument panel center --> Switch in center of instrument panel, removing
and installing.
 Remove A/C control head - 4 - --> 87 AIR CONDITIONING .

 Remove side instrument cluster cover on front passengers side --> 68 - INTERIOR EQUIPMENT .
 Remove cover in footwell on drivers side --> 68 - INTERIOR EQUIPMENT .
NOTE:  Two versions of panel - 2 - are installed in the Touareg, a panel with
threaded pin - 3 - and clamping washer - 4 - or a panel without threaded
pin and clamping washer.
 Clamping washer - 4 - is depicted as partially removed in the illustration
for a better overview. While installed, clamping washer is accessible
through radio system cut-out, however it is not visible.
 Clamping washer - 4 - is destroyed upon removal and must be replaced
during installation.
 Using a small screwdriver through the radio system cut-out, pry up wing - 5 - of clamping washer - 4 -
and pull off clamping washer - 4 - from threaded pin - 3 -.
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 Pry panel - 2 - out of mounts using trim removal wedge T10039/1 and unclip adjustment wheel housing -
1 - from panel.
 In vehicles with adjustment wheel housing light, disconnect harness connector from adjustment wheel
housing - 1 - and remove adjustment wheel housing - 1 -.
 Pry decorative strip - 6 - out of mounts using wedge T10039/1.
Fig. 386: Removing/Installing Instrument Panel Bracket Mounting Bolts & Bracket
 Remove mounting bolts - 1 - and remove bracket - 2 - from instrument panel.
Fig. 387: Identifying Glove Compartment Lining Mat

 Open glove compartment and remove lining mat - 1 - from glove compartment.
 Remove Glove Compartment Light W6 --> Glove Compartment Light W6 , removing and installing.
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Fig. 388: Remove/Install Lower Instrument Panel & Mounting Bolts Component
 Route all wiring harnesses which lead inward through lower section of instrument panel - 2 - so as to be
able to remove lower section of instrument panel - 2 -.
 Remove mounting bolts - 1 - (13 mounting bolts total) and remove lower section of instrument panel - 2 -
from instrument panel.
Fig. 389: Identifying Range/Cornering Lamp Control Module Harness Connector

 Disengage harness connector - 2 - and disconnect harness connector - 2 - from Headlamp

Range/Cornering Lamp Control Module J745 - 1 -.
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Fig. 390: Removing/Installing Range/Cornering Lamp Control Module Bracket & Bolts
 Remove mounting bolts - 1 - and remove bracket - 2 - with Headlamp Range/Cornering Lamp Control
Module J745 in - direction of arrow -.
Fig. 391: Identifying Range/Cornering Lamp Control Module & Bracket

 Clip retaining hooks inward - arrows - and remove Headlamp Range/Cornering Lamp Control Module
J745 - 2 - from bracket - 1 -.
Installing:
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NOTE:  Before installing, check whether a securing clip is installed in center of

panel - 2 - as in the area of the threaded pin - 3 -. If this is not the case, a
securing clip must be installed at this location.
 If a panel without threaded pin and clamping washer was installed in the
vehicle and the panel is replaced by a version with threaded pin and
clamping washer, the securing clip in the area of the threaded pin must
then be removed before the installation.
 Use a new clamping washer - 4 - for the installation.
 After installing panel - 2 - , the new clamping washer - 4 - must be inserted
to stop (do not turn!) in the depicted position.
Fig. 393: Identifying Center Console Bolts & Brackets

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 Tighten mounting bolts for bracket - 7 - in the following sequence.
 Mounting bolt 1
 Mounting bolt 6
 Mounting bolt 3
 Mounting bolt 4
 Mounting bolt 2
 Mounting bolt 5
NOTE:  After installing a new Headlamp Range/Cornering Lamp Control Module,

control module must be coded and then basic setting of headlamps must
be performed --> 01 - MAINTENANCE .

Coding Headlamp Range/Cornering Lamp Control Module J745
Fault Finding".
sequence:
 Body

 Code Control Module for AFS Light Control
NOTE:  If Headlamp Range/Cornering Lamp Control Module J745 is coded, basic

setting of headlamps must be performed after coding --> 01 -
MAINTENANCE .
Output Diagnostic Test Mode (DTM) of Headlamp Range/Cornering Lamp Control Module J745
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 Left Headlamp Beam Adjustment Motor V48 and Right Headlamp Beam Adjusting Motor V49
 Left Dynamic Cornering Light Motor V318 or Right Dynamic Cornering Light Motor V319
 Left Cornering Lamp L148 or Right Cornering Lamp L149
NOTE:  Malfunctions of the range control and AFS (Adaptive Front lighting
System) systems are indicated by the "Lamp failure" indicator light in the
instrument cluster.
Fault Finding".
sequence:
 Body

 Output Diagnostic Test Mode (DTM) of AFS
The vehicle level sensors are a component of automatic headlamp range control.
The Vehicle Level Sensors transmit vehicle level in the form of a PWM signal (pulse-width modulated signal)
to the Headlamp Range/Cornering Lamp Control Module J745.
two plus-wires and one Ground (GND) wire. Voltage is supplied to Left Front Level Control System Sensor
Left Front Level Control System Sensor G78 , removing and installing --> 40 - FRONT SUSPENSION .
Left Rear Level Control System Sensor G76 , removing and installing --> 42 - REAR SUSPENSION .
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Checking Vehicle Level Sensor
Left Front Level Control System Sensor G78 and Right Front Level Control Sensor G289 , checking.
Level Control System Control Module J197 transmits this signal to the Headlamp Range/Cornering Lamp
Left Front Level Control System Sensor G78 and Right Front Level Control Sensor G289 , removing and
installing --> 40 - FRONT SUSPENSION .
Left Rear Level Control System Sensor G76 and Right Rear Level Control System Sensor G77 , removing and
installing --> 42 - REAR SUSPENSION .
Checking Vehicle Level Sensor
Left Front Level Control System Sensor G78 and Right Front Level Control Sensor G289 , checking.
Checking vehicle level sensor
Fault Finding".
sequence:
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 Body
 Automatic headlamp range control electrical components

 Level control system sensor
Adjusting headlamps
 Notes on hazardous high voltage/currents --> Information on dangerous high voltage/current

 Notes on pressure, temperature and radiation/electric arc --> Notes on pressure, temperature and
radiation/glare
 Assembly notes for gas discharge lamps --> Assembly notes on gas discharge lamps
 Disposal regulations for gas discharge lamps --> Disposal regulations for gas discharge lamps
 Gloves
Information on dangerous high voltage/current

ignition key.
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system.

Halogen lamps.

and gloves.

be switched off.
ignition key.


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collection point.
FOG LAMPS
Fog lamps
Owners Manual
Vehicle electrical system control is equipped with On Board Diagnostics (OBD) which assists troubleshooting
of fog lights.
Fog lamp, removing and installing
NOTE:  Illustrations depict removal and installation at left fog light.

 Vehicles from 12/06, the form of the fog light cover cap has changed.
Removal and installation of the fog light is done in the same way.
Removing:
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Fig. 394: Identifying Cover Caps

 Release cover cap - 1 - from locking devices in - direction of arrow -.
Fig. 395: Releasing Cover Cap In Direction Of Arrow From Locking Devices & Removing Cover Cap
 Release cover cap - 1 - in - direction of arrow - from locking devices and remove cover cap - 1 -.
Fig. 396: Identifying Hex Socket Head & Screws

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Fig. 397: Identifying Headlamp Mounting Bolt

 Remove mounting bolt - 1 - above headlamp and remove washer - 2 -.
Fig. 398: Identifying Fog Light Housing

 Remove fog light housing from bumper and disconnect harness connector - arrow -.
Installing:

 Check fog lamp adjustment and adjust if necessary --> 01 - MAINTENANCE .
Fog lamp , removing and installing
Removing:
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 Remove fog lamp --> Fog lamp, removing and installing.
Fig. 399: Turning Lamp Socket In Direction Of Arrow & Removing It From Fog Lamp
 Turn lamp socket in - direction of arrow - and remove it from fog lamp.
The fog lamp bulb is permanently attached to the bulb socket and cannot be replaced separately.
Fog lamp bulb : H11 12 V/55 W
Installing:
 Tighten mounting bolts to specified tightening torque --> Tightening Torques: Fog lamps.
 Next, check function of headlamp.
 Check fog light adjustment and adjust if necessary --> 01 - MAINTENANCE .
Fog lamp, checking
Fog lamps (Left Front Fog Lamp L22 and Right Front Fog Lamp L23) can be checked via output Diagnostic
Fog lamp, adjusting
Adjusting fog lights --> 01 - MAINTENANCE
Fog lights (model variation)
On vehicles with increased fording depth (PR no. 6GB, 6GC), an additional fog light venting valve is installed.
It prevents the fog lights from fogging.
NOTE:  When replacing the fog light, a new venting valve should be used.
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EXTERIOR MIRROR TURN SIGNAL LAMP AND ENTRY LAMP IN OUTSIDE MIRROR
Exterior mirror turn signal lamp and Entry lamp in outside mirror
Exterior mirror turn signal lamps (side turn signal lights) are installed in exterior mirror housing.
Fig. 400: Identifying Mirror Turn Signals And Entry Lights In Exterior Mirror
In addition, there is one entry lamp each in exterior mirror housings which illuminate the dark entry area around
opened drivers and front passengers door.
1 - Drivers Entry Lamp (in outside mirror) W52 and Front Passengers Entry Lamp (in outside mirror) W53
2 - Drivers Exterior Mirror Turn Signal Lamp L131 and Front Passengers Exterior Mirror Turn Signal Lamp
L132
Comfort system is equipped with On Board Diagnostics (OBD), which assists troubleshooting of exterior mirror
turn signal lamp and entry lamps in exterior mirror.
Mirror turn signals
Left Mirror Turn Signal Lamp L131 and Right Mirror Turn Signal Lamp L132 , removing and installing
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NOTE:  No standard lamps are installed in mirror turn signals, rather long-lasting
light-emitting diodes (LEDs).
 If damaged, the entire turn signal must be replaced.
 Removing and installing drivers side lamp and passengers side lamp is
performed in the same manner on both sides and is only described for one
side.
Removing:
 Removing lamp for mirror flasher --> 66 - EXTERIOR EQUIPMENT .
Installing:
 Installing mirror turn signal lamp --> 66 - EXTERIOR EQUIPMENT .
Mirror turn signal lamp , checking
Left Mirror Turn Signal Lamp L131 and Right Mirror Turn Signal Lamp L132 can be checked via output
Diagnostic Test Mode (DTM) of Comfort System Central Control Module J393.
Entry lamps in exterior mirrors
Drivers Entry Lamp (in outside mirror) W52 and Front Passengers Entry Lamp (in outside mirror) W53 , removing and
installing
NOTE:  Removing and installing drivers side light and passengers side light is
performed in the same manner on both sides and is only described for one
lamp.
Removing:
 Remove entry lamp in outside mirror --> 66 - EXTERIOR EQUIPMENT .
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Fig. 401: Identifying Socket With Bulb And Housing

 Remove socket with lamp - 1 - from housing - 2 -.
Fig. 402: Identifying Bulb And Socket

 Remove plug-in socket lamp from holder.
Plug-in socket lamp: 12 V, 5 W
Installing:
Drivers Entry Lamp (in outside mirror) W52 and Front Passengers Entry Lamp (in outside mirror) W53 , checking
Drivers Entry Lamp (in outside mirror) W52 and Front Passengers Entry Lamp (in outside mirror) W53 can be
checked via output Diagnostic Test Mode (DTM) of Comfort System Central Control Module J393.
TAILLIGHTS
Taillights
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Taillights
S - Taillamps
B - Brake lights
B - Turn signals
R - Back-up lights
Comfort System and Vehicle Electrical System are equipped with On Board Diagnostics (OBD) which assists
troubleshooting of tail light assemblies.
Taillights in side panel, assembly overview
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Fig. 403: Taillights In Side Panel, Assembly Overview

- Tightening torques --> Tightening Torques: Taillamp assembly in side panel
1 - Connector
 For taillamp assembly in side panel
2 - Bulb holder
 Removing and installing --> Taillight bulb carrier in side panel, removing and installing
3 - Left Rear Turn Signal Lamp M6 and Right Rear Turn Signal Lamp M8
 12 V/PY 21 W
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 Checking
4 - Left Brake/Tail Light M21 and Right Brake/Tail Light M22
 12 V/P 21 W/4 W
 Checking
5 - Cover
6 - Screws
 For taillamp assembly in side panel
7 - Lock nut
8 - Housing
 Removing and installing --> Taillights in side panel, removing and installing
 Gap dimensions --> Taillight gap dimensions
NOTE:  Gap dimensions of tail light assembly in side panel can only be adjusted
using the adjustable tail light assembly carrier which is not installed at the
factory.
 Adjustable tail light assembly carrier in side panel --> Adjustable taillamp
assembly carrier in side panel
9 - Ball head
10 - Plastic clip nut
 Replace for every removal of the taillamp assembly
11 - Bracket
 Installing adjustable tail light assembly carrier
Taillights in side panel, removing and installing
Removing:
CAUTION:  Do not pry out back-up light using a screwdriver, plastic wedge or
similar tool.
 There is the danger of damaging the taillamp assembly or vehicle
paint.
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 If taillamp assembly cannot be disengaged by hand, the hook for

front end 3370 can be used as an aid as described below.
Fig. 404: Identifying Mounting Bolt cover Caps

 Unclip cover caps - arrows - of mounting bolts at tail light assembly.
Fig. 405: Identifying Tail Light Screws

NOTE:  Housing for taillamp assembly is also secured to mounting bolts with a
ball head in a securing clip. For deviating gap dimensions, an adjustable
taillamp assembly carrier must be installed with a plastic clip nut -->
Adjustable taillamp assembly carrier in side panel.
CAUTION:  Taillamp assembly may be destroyed.

 Do not tip and turn taillamp assembly too far in direction of arrow 1 in
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Fig. 406, otherwise the taillamp lens will break.

 If taillamp assembly cannot be disengaged by hand, the hook for
front end 3370 can be used as an aid.
Fig. 406: Rotating Taillamp Assembly In Direction Of Arrow Until Housing Can Be Seen At Upper Gap,
While Simultaneously Pulling Taillamp Assembly In Direction Of Arrow
 Rotate taillamp assembly in - direction of arrow 1 - until housing can be seen at upper gap.
Simultaneously pull taillamp assembly by hand in - direction of arrow 2 -.
Fig. 407: Identifying Tail Lamp Harness Connector

 Disengage harness connector - arrow - and disconnect it.
NOTE:  If taillamp assembly cannot be removed by hand, proceed as follows:
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Fig. 408: Identifying Special Hook 3370

 Special hook 3370
Fig. 409: Guiding Hook For Front End 3370 Into Gap Under Taillamp Assembly
 Cover bumper cover - 3 - with standard adhesive tape below taillamp assembly - 1 - to protect the paint.
 Guide hook for front end 3370 - 2 - into gap under taillamp assembly - 1 - as depicted in the illustration.
Fig. 410: Exploded View Of Taillamp Assembly

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 Carefully slide hook for front end 3370 on to position depicted in the illustration.
NOTE:  Magnified area in the illustration makes it clear at which location the hook
for front end 3370 must be positioned to pull out the taillamp assembly.
 Using the hand on the T-handle of hook for front end 3370 , pull taillamp assembly - 1 - toward rear.
 Support the pulling motion by also pulling and supporting with free hand in upper area of taillamp
assembly - arrow A -.
CAUTION:  Taillamp assembly wiring harness may be damaged.

 Carefully unlock taillamp assembly and pay attention to lengths of
connected wires.
Fig. 411: Identifying Tail Lamp Harness Connector

 Disengage and disconnect harness connector - arrow -.
Installing:
NOTE:  Plastic clip nut - 1 - must be replaced after each removal of the taillamp
assembly!
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Fig. 412: Identifying Ball Head & Plastic Clip Nut

 Connect harness connector.

 Insert taillamp assembly housing into body cut-out and push ball head - 2 - into new plastic clip nut - 1 -
while doing so.
 Bring housing for tail light assembly into correct position to the body by hand, hold firmly and then
tighten mounting bolts.
 Check gap dimension --> Taillight gap dimensions.
Taillight bulb carrier in side panel, removing and installing
Removing:
 Remove taillamp assembly in side panel --> Taillights in side panel, removing and installing.
Fig. 413: Releasing Retaining Straps & Removing Lamp Carrier

 Release retaining straps - arrows - and remove lamp carrier - 1 -.
Installing:
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Adjustable taillamp assembly carrier in side panel
NOTE:  By e.g. damage to rear side panel or by replacing tail light assembly, it
may be necessary to adapt tail light assembly by reason of unacceptable
gap dimensions (body to tail light assembly). For this, an adjustable tail
light assembly carrier must be installed.
 For technical reasons, it is not possible to offer a side panel with hole-
punched holder for tail light assembly if repairs are required. In this case,
a specially developed adjustable tail light assembly carrier is available,
which must also be installed.
Fig. 414: Identifying Adjustable Lamp Carrier Components

The adjustable lamp carrier consists of:
 1x - A - Clip mount 1.2 mm with plastic clip nut

 2x - B - Spacer pieces, 1 mm
 2x - C - Spacer pieces, 0.5 mm
 1x - D - Threaded plate
 1x - E - Mounting bolt
 1x - F - Mounting bolt
Adjustable taillamp assembly carrier - assembly overview
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Fig. 415: Adjustable Taillamp Assembly Carrier - Assembly Overview

1 - Threaded plate (4.0 mm thick)
2 - Clip mount (1.2 mm thick)
3 - Plastic clip nut
4 - Mounting plate
5 - Spacer piece (0.5 mm thick)
7 - Spacer piece (1.0 mm thick)
Adjustable taillamp assembly carrier, installing
Fig. 416: Adjustable Taillamp Assembly Carrier, Installing

Prepare side panel for installation of adjustable tail light assembly carrier:
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 Place one spacer piece positioned at center on retaining plate and mark the diameters - G - and - H -.
 Drill holes to dimensions - G - = 8 mm and - H - = 22 mm using a center-bit.
 Perform the required corrosion protection measures Corrosion protection measures; corrosion protection.
Fig. 417: Removing/Installing Adjustable Tail Light Assembly Carrier

Installing adjustable tail light assembly carrier:
 Place clip mount with plastic clip nut behind mounting plate.
 Place adjustment shims underneath as necessary, press on threaded plate with internal thread behind body
plate and screw in mounting bolts so that the carrier can still be positioned.
 Position carrier at center.
 Tighten mounting bolts to specified tightening torque --> Tightening Torques: Taillamp assembly in
side panel.
 Install tail light assembly --> Taillights in side panel, removing and installing.
 Check gap dimensions --> Taillight gap dimensions.
Fig. 418: Removing/Installing Adjustable Tail Light Assembly Carrier

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 If required, remove tail light assembly again, position lamp carrier anew or adjust using spacer pieces.
NOTE:  If it is necessary, the plastic clip nut in clip mount can be shortened at the
side overhangs - x -. This increases the adjustment range.
Taillights in rear lid, assembly overview
Fig. 419: Taillights In Rear Lid, Assembly Overview

- Tightening torques --> Tightening Torques: Taillamp assembly in rear lid
1 - Housing
 Removing and installing --> Taillights in rear lid, removing and installing
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 Gap dimensions --> Taillight gap dimensions
2 - Left Back-Up Light M16 and Right Back-Up Light M17
 12 V/H 21 W
 Checking
3 - Left Tail Light Lamp 2 M49 and Right Tail Light Lamp 2 M50
 12 V/P 21 W/4 W
 Checking
4 - Bulb holder
 Removing and installing --> Taillight bulb carrier in side panel, removing and installing
5 - Connector
 For tail light assembly in rear lid
6 - Nuts
 For tail light assembly in rear lid
7 - Left Rear Fog Light L46 and Right Rear Fog Light L47
 12V/P 21 W
 Checking
Taillights in rear lid, removing and installing
Removing:
 Open rear lid.
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Fig. 420: Identifying Clip Service Cover

 Clip service cover - 1 - out of locking mechanisms and pull off cover in - direction of arrow -.
Fig. 421: Identifying Tail Light Assembly Mounting Nuts

 Disconnect connector - arrow -.

 Remove mounting nuts - 1 - and remove housing for tail light assembly.
Installing:
 Bring housing for tail light assembly into correct position to the body by hand, hold firmly and then
tighten mounting nuts.
 Tighten mounting nuts to specified tightening torque --> Tightening Torques: Taillamp assembly in
rear lid.
 Check gap dimension of tail light assembly --> Taillight gap dimensions.
Taillight bulb carrier in rear lid, removing and installing
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Removing:
 Open rear lid.
Fig. 422: Identifying Clip Service Cover

 Clip service cover - 1 - out of locking mechanisms and pull off cover in - direction of arrow -.
Fig. 423: Identifying Tail Light Assembly Mounting Nuts

 Disconnect connector - arrow -.
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Fig. 424: Releasing Retaining Strap & Remove Lamp Carrier

 Release retaining strap - arrow - and remove lamp carrier - 1 -.
Installing:
Taillight gap dimensions
Fig. 425: Taillight Gap Dimensions

1 - Gap dimension
 4 mm +/- 0.5 mm
2 - Gap dimension
 1.0 mm +/-0.2 mm
3 - Flushness
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 0.5 mm +/- 0.5 mm
LICENSE PLATE LIGHTS
License Plate Lights
Comfort system is equipped with On Board Diagnostics (OBD) which assists troubleshooting of license plate
lights.
Left License Plate Light X4 and Right License Plate Light X5 , removing and installing
Removing:
Fig. 426: Identifying License Plate Mounting Bolts

 Remove mounting bolts - arrows - of Left License Plate Light X4 and Right License Plate Light X5.
 Remove Left License Plate Light X4 and Right License Plate Light X5.
 Disconnect harness connector of Left License Plate Light X4 and Right License Plate Light X5.
Installing:

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Left License Plate Light X4 and Right License Plate Light X5 , checking
Left License Plate Light X4 and Right License Plate Light X5 can be checked via output Diagnostic Test Mode
(DTM) Comfort System Central Control Module J393.
HIGH-MOUNT BRAKE LIGHT M25
High-mount Brake Light M25
Comfort system is equipped with On Board Diagnostics (OBD) which assists troubleshooting of additional
brake lights.
High-mount Brake Light M25 , removing and installing
NOTE:  Washer nozzle of rear window wiper is a component of High-mount Brake

Light M25 and cannot be adjusted.
 If wash sprays unevenly or does not spray the wiper area, replace High-
mount Brake Light M25 with wash (repair measure).
Removing:
Fig. 427: Releasing Cover From Locking Mechanisms

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 Release cover - arrow - from locking mechanisms.
Fig. 428: Identifying Nuts

Fig. 429: Identifying High-Mount Brake Light & Disconnect Harness Connector
 Lift rear spoiler with High-mount Brake Light M25 and disconnect 2-pin harness connector - 1 -.
 Disconnect hose connection - arrow - to wash of rear window wiper.
 Store the rear spoiler with High-mount Brake Light M25 on an appropriate surface.
 Remove bolts - 2 -.
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Fig. 430: Identifying High-Mount Brake Light & Locking Mechanisms

 Clip High-mount Brake Light M25 - 1 - in - direction of arrow - out of locking mechanisms - 2 -.
Installing:
NOTE:  When installing rear spoiler with High-mount Brake Light M25 , make sure
that hose (Velcro connection) to wash of rear window wiper and line
(Velcro connection) to High-mount Brake Light M25 are fitted properly.
High-mount Brake Light M25 , checking
High-mount Brake Light M25 can be checked via output Diagnostic Test Mode (DTM) of Comfort System
Central Control Module J393.
STEERING COLUMN SWITCH
Steering column switch
NOTE:  After installing a new Steering Column Electronic Systems Control Module
J527 , it must be coded --> Steering Column Electronic Systems Control
Module J527.
 If malfunctions occur at steering column switch, output Diagnostic Test
Mode (DTM) of Steering Column Electronic Systems Control Module J527
must be performed.
Microsoft
Owners Manual
Steering Column Electronic Systems Control Module J527 is equipped with On Board Diagnostics (OBD)
which assists troubleshooting.
Steering column switch - assembly overview
NOTE:  The following components of the steering column switch cannot be

disassembled:
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Fig. 431: Steering Column Switch - Assembly Overview

- Tightening torques --> Tightening Torques: Steering column switch
NOTE:  Also, if only one individual component of steering column switch is

removed or replaced, the sequence as described in --> Steering column
switch, disassembling and assembling must always be followed.
1 - Steering Column Electronic Systems Control Module J527
 Removing and installing --> Steering column switch, disassembling and assembling
 Coding
 Multi-pin connector assignment --> Steering column switch, pin assignment
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2 - Steering column
3 - Left trim of steering column switch
 On Steering Wheel Tiptronic Switch E389 at left
4 - Steering Wheel Tiptronic Switch E389 at left
5 - Bracket
 On Steering Wheel Tiptronic Switch E389 at left
6 - Torx bolt
 For mounting Steering Wheel Tiptronic Switch E389 at left and right sides
7 - Bracket
 For multi-pin harness connectors of Steering Wheel Tiptronic Switch E389 , Airbag Spiral Spring/Return
Spring With Slip Ring F138 and Steering Angle Sensor G85
8 - Multi-pin harness connector Steering Wheel Tiptronic Switch E389
9 - Bracket
 At steering wheel tiptronic switch E389 , right
10 - Steering Wheel Tiptronic Switch E389 at right
11 - Right trim of steering column switch
12 - Torx bolt
 For mounting Steering Wheel Tiptronic Switch E389 at left and right sides
13 - Windshield wiper switch
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 "Windshield wiper switch" consists of the components Windshield Wiper/Washer Switch E22 and
Windshield Wiper Intermittent Regulator E38
14 - Airbag spiral spring/return spring with slip ring F138 and steering angle sensor G85
15 - Socket head bolt
 For fastening steering column switch
16 - Turn Signal Switch
 Depending on equipment, the "turn signal switch" consists of the Turn Signal Switch E2 , Headlamp
Dimmer/Flasher Switch E4 , Parking Lamp Switch E19 and Adaptive Cruise Control Button E357
Steering column switch, removing and installing

Removing:
NOTE:  Wheels must be located in straight ahead position.

 Airbag Spiral Spring/Return Spring With Slip Ring F138 and Steering Angle
Sensor G85 must not be twisted out of center position during removal.
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 Airbag Spiral Spring/Return Spring With Slip Ring F138 and Steering Angle
Sensor G85 remain on steering column switch during removal.
 Using electric or mechanical adjustment mechanism, drive steering wheel out completely and move to
lowest position.


 Remove the driver airbag --> 69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS .
 Remove steering wheel --> 69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS .

Fig. 434: Identifying Trim Cover

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 Pry trim panel - arrow - at right out of locking mechanisms using wedge T10039/1 and slide outward.
 Trim panel at left is arranged symmetrically and must be pried out of locking mechanisms using wedge
T10039/1 and pushed outward.
NOTE:  Do not disassemble the covers.
Fig. 435: Identifying Upper/Lower Cover

 Move upper trim - arrow - of steering column switch upward and remove trim.
 Move lower trim - arrow - of steering column switch downward and remove trim.
Fig. 436: Identifying Socket Head Bolt

 Remove hex socket head bolt - arrow - , beneath steering column switch.
 Remove the steering column switch.
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Fig. 437: Identifying Retaining Clip Of Wiring Harness

 Press the retaining clip off from the wiring harness - arrow -.
Fig. 438: Identifying Connectors For Steering Column Switch

 Disconnect harness connectors - arrows - from steering column switches.
Installing:
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Fig. 439: Identifying Socket Head Bolt

 Tighten hex socket head bolt - arrow - to specified tightening torque --> Tightening Torques: Steering
column switch.
Fig. 440: Guiding In Lower Steering Column Switch Cover

 Guide in the lower steering column switch cover as shown - arrows -.

 Install steering wheel --> 69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS .
 Install airbag unit on drivers side --> 69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS .
Steering column switch, disassembling and assembling
NOTE:  Also, if only one individual component of steering column switch is

removed or replaced, the sequence described in the following must always
be adhered to.
Disassembling:
 Remove steering column switch --> Steering column switch, removing and installing.
Microsoft
Fig. 441: Identifying Bolts On Bridge For Tiptronic Switch

 Remove both bolts - arrows - at bridge of Steering Wheel Tiptronic Switch E389.
Fig. 442: Identifying Bolts On Tiptronic Switches

 Remove both bolts - arrows - at Steering Wheel Tiptronic Switch E389.
Fig. 443: Identifying Retainer, Holder, And Multi-Pin Connectors

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 Release locking mechanism - arrow - at multi-pin harness connector of Airbag Spiral Spring/Return
Spring With Slip Ring F138 and of Steering Angle Sensor G85 - 1 -.
 Carefully set aside bracket - 2 - with multi-pin harness connector for Steering Wheel Tiptronic Switch
E389 - 3 -.
Fig. 444: Identifying Retainer On Bridge Of Right Tiptronic Switch

 Release locking mechanism - arrows - at bridge of right Steering Wheel Tiptronic Switch E389.
 Carefully set aside bridge with right Tiptronic switch.
Fig. 445: Identifying Retainer On Bridge Of Left Tiptronic Switch

 Release locking mechanism - arrows - at bridge of left Steering Wheel Tiptronic Switch E389 and
remove the complete Steering Wheel Tiptronic Switch E389.
 Carefully remove Airbag Spiral Spring/Return Spring With Slip Ring F138 and Steering Angle Sensor
G85 from steering column switch.
NOTE:  Airbag Spiral Spring/Return Spring With Slip Ring F138 and Steering Angle
Sensor G85 must not be twisted out of center position during removal.
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Fig. 446: Identifying Bolts

 To remove "windshield wiper switch" , remove bolts - 2 -.

 Remove "windshield wiper switch".
 To remove "turn signal switch" , remove bolts - 1 -.
 Remove "turn signal switch".
 Remove Steering Column Electronic Systems Control Module J527 from "turn signal switch".
Assembly:
Assemble in reverse order of disassembly, observing the following:
NOTE:  If Steering Column Electronic Systems Control Module J527 is replaced, it

must be coded --> Steering Column Electronic Systems Control Module
J527.
 Make sure wires are routed correctly at steering column switch.
Steering column switch, pin assignment
Fig. 447: Steering Column Switch Pin Assignment

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I - Multi-pin connector for electrical Easy Entry
II - Multi-pin harness connector for Steering Wheel Tiptronic Switch E389
III - Multi-pin harness connector for Airbag Spiral Spring/Return Spring With Slip Ring F138 and Steering
Angle Sensor G85
IV - Multi-pin harness connector for voltage supply, CAN and terminal 15
I - Connector, 4-pin
Fig. 448: Identifying Multi-Pin Connector

1 - Electrical Easy Entry on/off
2 - Direction selection
3 - Terminal 31, negative
4 - not in use
II - Connector, 5-pin
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1 - not in use
2 - not in use
3 - not in use
5 - Tiptronic
III - Connector, 4-pin

3 - Spiral spring connection
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IV - Connector, 16-pin

3 - Powertrain-CAN, shielded
4 - not in use
5 - CCS switch setting "Off"
6 - not in use
7 - not in use
8 - CAN-comfort, Low
9 - CAN-comfort, High
10 - Drive system CAN High
11 - Drive system CAN Low
12 - not in use
13 - Terminal 15
14 - not in use
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15 - not in use
16 - not in use
Steering Column Electronic Systems Control Module J527
Steering Column Electronic Systems Control Module J527 , coding
Fault Finding".
sequence:
 Body
 Steering wheel electronics
 Functions of steering wheel electronics

 Code Control Module for steering wheel electronics
Steering Column Electronic Systems Control Module J527 , output Diagnostic Test Mode (DTM)
Fault Finding".
sequence:
 Body
 Steering wheel electronics
 Functions of steering wheel electronics

 Output Diagnostic Test Mode (DTM) of steering wheel electronics
REAR WINDOW OPENING
Rear window opening
Microsoft
Owners Manual
Comfort System and Vehicle Electrical System are equipped with On Board Diagnostics (OBD) which assists
troubleshooting of rear window opening.
Rear window, emergency release
Fig. 452: Identifying Release Cable & Locking Mechanism

If vehicle voltage supply is disrupted or Rear Window Opening Button E361 is malfunctioning, rear window
can be opened by operating the emergency release.
 Remove lower trim for tailgate --> 70 - INTERIOR TRIM .

 Disengage release cable - 1 - out of locking mechanism - 2 -.
 Pull release cable - 1 - in - direction of arrow -.
Rear Window Opening Button E361 , removing and installing
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Removing:
Fig. 454: Identifying Hex Nut

 Remove hex nut - 1 -.

 Open rear window, rear window emergency release --> Rear window, emergency release.
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Fig. 455: Identifying Release Cap

 Release cap - 1 - in - direction of arrow - from locking devices and remove it.
Fig. 456: Identifying Insulation

 Slide insulation - 1 - to the side in - direction of arrow - and thus expose the harness connector.
Fig. 457: Identifying Electrical Connector

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 Disconnect electrical connection - arrow -.
Fig. 458: Identifying Rear Window Opening Button Nuts


 Remove lock bracket - 1 - and wiper shaft with crank - 2 -.
 Remove Rear Window Opening Button E361.
Installing:
Fig. 459: Identifying Rear Window Opening Button Nuts

 Tighten mounting nuts - arrows - to specified tightening torque --> Tightening Torques: Rear window
opening.
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Fig. 460: Identifying Hex Nut

 Tighten hex nut - 1 - to specified tightening torque --> Tightening Torques: Rear window opening.
 Install wiper arm.
Rear Window Unlock Unit V312 , removing and installing
 Removing and installing Rear Window Unlock Unit V312 --> 55 - HOOD, LIDS .
ACCESS/START AUTHORIZATION
Access/start authorization
NOTE:  Access/Start Authorization Switch E415 (starter switch) with integrated

lock cylinder is one unit and can only be replaced completely.
 If Access/Start Control Module J518 is replaced, work sequence must be
performed.
Access/Start Authorization Switch E415 possesses an electronic terminal control.
Anti-Theft Engine Disable Sensor D1 and Ignition Switch Key Lock Solenoid N376 are integrated in
Access/Start Authorization Switch E415 and cannot be replaced separately.
All malfunctions in relation to Access/Start Authorization Switch E415 are output via Access/Start Control
Module J518.
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For this vehicle, the ignition key removal lock is enabled electro-mechanically.
NOTE:  To remove ignition key in vehicles with automatic transmission, always

shift selector lever into position "P" and then switch off ignition.
Otherwise the Ignition Switch Key Lock Solenoid N376 prevents removal
of the ignition key (ignition key removal lock)!
Ignition key removal lock ensures that ignition key is secured against unintentional removal.
Ignition key removal lock can be checked via output Diagnostic Test Mode (DTM) of Access/Start Control
Module J518.
Access/start authorization is equipped with On Board Diagnostics (OBD) which assists troubleshooting.
Emergency release of ignition key
If the voltage supply in the vehicle has been interrupted, the ignition key can be removed by actuating the
emergency release.
 Turn the ignition key to the "OFF" position.
Fig. 461: Identifying Push-Button

 Depress the push-button - arrow - with a screwdriver and hold.

 The ignition key may now be removed.
Access/Start Authorization Switch E415
Access/Start Authorization Switch E415 , removing and installing

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CAUTION: When removing and installing components in visible area (switches,

covers, trim, etc.), cover by taping the areas at which a prying tool (plastic
wedge, screwdriver) will be positioned using commercially available
adhesive tape.
NOTE:  Access/Start Authorization Switch E415 with integrated lock cylinder,

integrated Anti-Theft Engine Disable Sensor D1 and integrated Ignition
Switch Key Lock Solenoid N376 is one component and can only be
replaced completely.
Fig. 462: Identifying Wrench T10152

 Wrench T10152


 Wedge T10039/1
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Removing:


 Remove radio or radio-navigation system --> 91 RADIO, TELEPHONE, NAVIGATION, TRIP
COMPUTER .
Fig. 464: Identifying Trim Strip

 Pry trim strip - 1 - out of locking mechanisms using wedge T10039/1.
Fig. 465: Placing Polydrive Key T10152 On Access/Start Authorization Switch E415 Into Cut-Outs Of
Mounting Nut
 Place polydrive key T10152 on Access/Start Authorization Switch E415 into cut-outs of mounting nut.
 Remove mounting nut of Access/Start Authorization Switch E415 and grasp Access/Start Authorization
Switch E415 through instrument cluster (radio or radio-navigation system removed) and guide
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Access/Start Authorization Switch E415 out.

 Disconnect multi-pin harness connector from Access/Start Authorization Switch E415.
Installing:
 Tighten mounting nut of Access/Start Authorization Switch E415 by hand using polydrive key T10152.
NOTE:  Adaptation or coding of Access/Start Authorization Switch E415 after

removing or installing is not necessary.
Connector assignment of Access/Start Authorization Switch E415
Fig. 466: Access/Start Authorization Button E408 , Pin Assignment

Connector, 12-pin
1 - Switch contact 2
2 - Solenoid for key lock
3 - Voltage supply, negative
4 - Anti-theft immobilizer, "shift lock"
8 - Immobilizer, Data 2
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9 - Voltage supply, positive
12 - Immobilizer, Data 1
Checking Access/Start Authorization Switch E415
Access/Start Authorization Switch E415 can be checked via output Diagnostic Test Mode (DTM) of
Access/Start Control Module J518.
Access/Start Authorization Button E408
The access/start authorization button E408 allows the vehicle to be started without actively using the ignition
key.
Access/start authorization button E408 , removing and installing
Removing:


 Remove gear selector cover --> 68 - INTERIOR EQUIPMENT .

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 Disconnect electrical connector.
 Remove Access/Start Authorization Button E408.
Installing:
NOTE:  Adaptation or coding of Access/Start Authorization Button E408 after

removing and installing is not necessary.
Access/Start Control Module J518
Access/start control module J518 , removing and installing
Removing:


 Remove lower storage compartment on drivers side --> 68 - INTERIOR EQUIPMENT .
Fig. 468: Push Locking Hooks Of Bracket Outward & Pull Access/Start Control Module J518 Behind
Bracket Forward
 Push locking hooks of bracket outward - arrows B - and pull Access/Start Control Module J518 - 1 -
behind bracket forward - arrow A -.
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Fig. 469: Removing/Installing Access/Start Control Module J518 Components

 Release - arrow A - locking mechanism - 1 - of multi-pin harness connector - 2 -.

 Disconnect - arrow B - multi-pin harness connector - 2 - from Access/Start Control Module J518.
 Disengage multi-pin harness connector - 3 - and disconnect it from Access/Start Control Module J518 -
arrow C -.
 Remove Access/Start Control Module J518 from bracket.
Installing:
 The strap - 1 - for Access/Start Control Module J518 must first be inserted into guide at top.
Fig. 470: Exploded View Of Strap Guide & Bracket

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 Next, strap - 2 - is clipped into bracket.
NOTE:  If Access/Start Control Module J518 is replaced, work sequence must be

performed.
Access/Start Control Module J518 , replacing
Fault Finding".
sequence:
 Body
 Anti-theft Immobilizer
 Functions
 Replacing the access/start control module
Access/Start Control Module J518 , output Diagnostic Test Mode (DTM)
The following components (depending on equipment) can be checked via output Diagnostic Test Mode (DTM)
of Access/Start Control Module J518 :
 Electronic steering column lock

 Activation of voltage supply relay, terminal 15
 Activation of voltage supply relay, terminal 15SV
 Activation of voltage supply relay, terminal 75X
 Ignition key removal lock

 Ignition/Starter Switch
 Access/Start Authorization antenna
Fault Finding".
sequence:
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 Body
 Body repair procedures
 Access/start authorization
 Functions
 Access/Start Control Module -J518-, output Diagnostic Test Mode (DTM)
Antenna and sensors for Access/Start Authorization
Antenna and sensors for Access/Start Authorization - assembly overview
Fig. 471: Antenna And Sensors For Access/Start Authorization - Assembly Overview
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1 - Rear left outer door handle
The following components are integrated in left rear outside door handle:
 Left access/start authorization antenna R134

 Left Rear Outside Door Handle Touch Sensor G417
 Left Rear Outside Door Handle Central Locking Button E371
NOTE:  Left Access/Start Authorization Antenna R134 has two parts. The first part
is located in the front outside door handle on drivers side. The second part
is also located on drivers side, but in the rear outside door handle. The
antennae must also be replaced separately (front and rear).
 The complete outer door handle must always be replaced if
malfunctioning.
 No coding, basic setting or adaptation is necessary when outside door
handle is replaced.
 Removing and installing left rear outside door handle
 Checking Left Access/Start Authorization Antenna R134
2 - Drivers side outside door handle
The following components are integrated in drivers side outside door handle:

 Drivers Outside Door Handle Touch Sensor G415
 Drivers Outside Door Handle Central Locking Button E369
malfunctioning.
handle is replaced.
 Removing and installing driver-side outside door handle
 Checking Left Access/Start Authorization Antenna R134
3 - Interior Access/Start Authorization Antenna 2 R139
 Component location: in center console, front

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 Checking
4 - Interior Access/Start Authorization Antenna 1 R138
 Component location: In front of shift lever

 Checking
5 - Passengers side outside door handle
The following components are integrated in passengers side outside door handle:
 Right access/start authorization antenna R135

 Front Passengers Outside Door Handle Touch Sensor G416
 Front Passengers Outside Door Handle Central Locking Button E370
NOTE:  Right Access/Start Authorization Antenna R135 has two parts. The first
part is located in the front outside door handle on passengers side. The
second part is also located on passengers side, but in the rear outside
door handle. The antennae must also be replaced separately (front and
rear).
malfunctioning.
handle is replaced.
 Removing and installing passenger-side outside door handle
 Checking Right Access/Start Authorization Antenna R135
6 - Right rear outside door handle
The following components are integrated in right rear outside door handle:

 Right Rear Outside Door handle Touch Sensor G418
 Right Rear Outside Door Handle Central Locking Button E372
rear).
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malfunctioning.
handle is replaced.
 Removing and installing right rear outside door handle
 Checking Right Access/Start Authorization Antenna R135
7 - Access/start authorization antenna (in rear bumper) R136
NOTE:  Access/Start Authorization Antenna (in rear bumper) R136 has two parts.
The first part is located in left side of rear bumper. The second part is
located in right side of rear bumper.
 Checking
8 - Luggage compartment access/start authorization antenna R137
NOTE:  Depending on equipment, Luggage Compartment Access/Start

Authorization Antenna R137 is located at three different positions in
luggage compartment.
 Checking
Driver-side outside door handle, removing and installing
The following components are integrated in drivers side outside door handle:

 Drivers Outside Door Handle Touch Sensor G415
 Drivers Outside Door Handle Central Locking Button E369
malfunctioning.
handle is replaced.
Removing:
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 Remove left front outside door handle --> 57 - FRONT DOORS, CENTRAL LOCKING SYSTEM .
Installing:
Passenger-side outside door handle, removing and installing
The following components are integrated in passengers side outside door handle:

 Front Passengers Outside Door Handle Touch Sensor G416
 Front Passengers Outside Door Handle Central Locking Button E370
rear).
malfunctioning.
handle is replaced.
Removing:
 Remove right front outside door handle --> 57 - FRONT DOORS, CENTRAL LOCKING SYSTEM .
Installing:
Left rear outside door handle, removing and installing
The following components are integrated in left rear outside door handle:

 Left Rear Outside Door Handle Touch Sensor G417
 Left Rear Outside Door Handle Central Locking Button E371
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malfunctioning.
handle is replaced.
Removing:
 Remove left rear outside door handle --> 58 - REAR DOORS .
Installing:
Right rear outside door handle, removing and installing
The following components are integrated in right rear outside door handle:

 Right Rear Outside Door handle Touch Sensor G418
 Right Rear Outside Door Handle Central Locking Button E372
rear).
malfunctioning.
handle is replaced.
Removing:
 Remove right rear outside door handle --> 58 - REAR DOORS .
Installing:
Access/Start Authorization Antenna (in rear bumper) R136 , removing and installing
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NOTE:  Access/Start Authorization Antenna (in rear bumper) R136 has two parts.
The first part is located on left side of rear bumper. The second part is
located on right side of rear bumper.
 No coding, basic setting or adaptation is necessary if Access/Start
Authorization Antenna (in rear bumper) R136 is replaced.
Removing:
 Remove rear bumper cover --> 63 - BUMPERS .
Fig. 472: Removing/Installing Antenna From Foam Piece Of Bumper Carrier

 Disconnect connectors - arrows - of antennae.

 Remove antenna - 1 - and - 2 - from foam piece of bumper carrier.
Fig. 473: Exploded View Of Clip

NOTE:  Depending on equipment, second part of antenna - 1 - can be secured
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directly to bumper carrier with two clips - 2 -.
Installing:
Luggage Compartment Access/Start Authorization Antenna R137 , removing and installing
Fig. 474: Exploded View Of Access/Start Authorization Antenna R137

Depending on equipment, Luggage Compartment Access/Start Authorization Antenna R137 - arrows - is

located at three different positions in luggage compartment.
NOTE:  No coding, basic setting or adaptation is necessary if Luggage

Compartment Access/Start Authorization Antenna R137 is replaced.
Removing:
 Remove storage area floor of luggage compartment from vehicle.
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Fig. 475: Identifying Luggage Compartment Access/Start Authorization Antenna R137 & Connector
 Loosen the glued Luggage Compartment Access/Start Authorization Antenna R137 - 1 - from luggage
compartment floor.
Installing:
Interior Access/Start Authorization Antenna 1 R138 , removing and installing
Fig. 476: Identifying Interior Access/Start Authorization Antenna 1 R138

Interior Access/Start Authorization Antenna 1 R138 - arrow - is located in center console, in front of shift
lever.
NOTE:  No further coding, basic setting or adaptation is necessary if Interior

Access/Start Authorization Antenna 1 R138 is replaced.
Removing:
 Remove center console --> 68 - INTERIOR EQUIPMENT .
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Fig. 477: Identifying Interior Access/Start Authorization Antenna 1 R138 Components

 Disconnect connector - 3 - for Interior Access/Start Authorization Antenna 1 R138 - 2 -.

 Guide retaining tab - 1 - for Interior Access/Start Authorization Antenna 1 R138 - 2 - out of mount - 4 -.
Installing:
Interior Access/Start Authorization Antenna 2 R139 , removing and installing
Fig. 478: Locating Interior Access/Start Authorization Antenna 2 R139

Interior Access/Start Authorization Antenna 2 R139 - arrow - is located in front portion of center console.
NOTE:  No coding, basic setting or adaptation is necessary if Interior Access/Start

Authorization Antenna 2 R139 is replaced.
Removing:
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 Depending on equipment, remove either Rear A/C Control Head (Climatronic) E265 --> 87 AIR
CONDITIONING , or front portion of center console --> 68 - INTERIOR EQUIPMENT .
Fig. 479: Identifying Interior Access/Start Authorization Antenna 2 R139 Components

 Disconnect connector - 1 - for Interior Access/Start Authorization Antenna 2 R139 - 3 -.

 Guide retaining tab - 4 - for Interior Access/Start Authorization Antenna 2 R139 - 3 - out of mount - 5 -.
Installing:
PARKING AID
Parking aid
NOTE:  Familiarity with the function and operation of the parking aid is essential
when addressing customer complaints.
Owners Manual
General information
The parking assistance system assists the driver during parking by signaling acoustically and optically the
distance to an obstruction in front of or behind the vehicle.
The parking aid system consists of:

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The following functions and components can be adapted:
 Adapting Parking Aid Loudspeaker R169

 Offset attachments (trailer hitch, Offroad spare wheel)
The parking aid system is equipped with On Board Diagnostic (OBD) capabilities which assists in
troubleshooting.
Perform output Diagnostic Test Mode (DTM) to test the entire parking assistance system.
Parking assistance system - assembly overview
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Fig. 480: Parking Assistance System - Assembly Overview

1 - Right front parking aid sensor
 Right Front Parking Aid Sensor G252 in front bumper cover

 Right Front Center Parking Aid Sensor G253 in front bumper cover
 Right Front Inner Parking Aid Sensor G333 in front bumper cover
 Removing and installing --> Front sensors for parking assistance, removing and installing
 Checking
2 - Left front parking aid sensor
 Left Front Parking Aid Sensor G255 in front bumper cover
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 Left Front Center Parking Aid Sensor G254 in front bumper cover
 Left Front Inner Parking Aid Sensor G332 in front bumper cover
 Removing and installing --> Front sensors for parking assistance, removing and installing
 Checking
3 - Left front parking aid display Y13
 Above storage compartment in center of instrument cluster

 Removing and installing --> Left Front Parking Aid Display Y13 , removing and installing
 Checking
4 - Parking Aid Loudspeaker R169
 On bracket for relay carrier and Vehicle Electrical System Control Module J519 in front left foot well
 Removing and installing --> Parking Aid Loudspeaker R169 , removing and installing
 Checking
 Adapting
5 - Parking Aid Button E266
 In instrument cluster, center

 Switch in center of instrument cluster, removing and installing --> Switch in center of instrument
panel, removing and installing
6 - Rear parking aid display Y15
 In molded headliner above rear window

 Removing and installing --> Rear Parking Aid Display Y15 , removing and installing
 Checking
7 - Parking Aid Control Module J446
 Behind the side panel trim in luggage compartment, left side

8 - Sensor for parking, rear
 Left Rear Parking Aid Sensor G203 in rear bumper cover

 Left Rear Center Parking Aid Sensor G204 in rear bumper cover
 Left Rear Inner Parking Aid Sensor G334 in rear bumper cover
 Right Rear Parking Aid Sensor G206 in rear bumper cover
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 Right Rear Center Parking Aid Sensor G205 in rear bumper cover
 Right Rear Inner Parking Aid Sensor G335 in rear bumper cover
 Removing and installing --> Rear sensors for parking assistance, removing and installing
 Checking
Parking Aid Control Module J446 , removing and installing
Parking Aid Control Module J446 is located behind side panel trim in luggage compartment, left side.
Parking Aid Control Module J446 , removing and installing
Removing:
 Remove left side panel trim --> 70 - INTERIOR TRIM
Fig. 481: Identifying Parking Air Control Module Connectors

 Disconnect connectors - arrows -.
Fig. 482: Identifying Parking Air Control Module Screws
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 Pry out pins - arrows - from clips.

 Remove Parking Aid Control Module J446 together with bracket out of vehicle.
Fig. 483: Removing/Installing Retaining Tabs & Removing Parking Aid Control Module J446 From
Bracket
 Disengage retaining tabs - arrows - and remove Parking Aid Control Module J446 from bracket.
Installing:
Adaptation of Parking Aid Control Module J446
The following functions can be adapted:
 Adapting front warning tone

 Adapting rear warning tone (only when 2 systems are installed)
 Offset attachments (trailer hitch, Offroad spare wheel)
Fault Finding".
sequence:
 Body
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 Parking aid
 Functions
 Adaptation
Output Diagnostic Test Mode (DTM) of Parking Aid Control Module J446
The following components can be checked via output Diagnostic Test Mode (DTM):
 Left Front Parking Aid Sensor G255 in front bumper cover

 Left Front Center Parking Aid Sensor G254 in front bumper cover
 Left Front Inner Parking Aid Sensor G332 in front bumper cover
 Right Front Parking Aid Sensor G252 in front bumper cover
 Right Front Center Parking Aid Sensor G253 in front bumper cover
 Right Front Inner Parking Aid Sensor G333 in front bumper cover
 Left Rear Parking Aid Sensor G203 in rear bumper cover
 Left Rear Center Parking Aid Sensor G204 in rear bumper cover
 Left Rear Inner Parking Aid Sensor G334 in rear bumper cover
 Right Rear Parking Aid Sensor G206 in rear bumper cover
 Right Rear Center Parking Aid Sensor G205 in rear bumper cover
 Right Rear Inner Parking Aid Sensor G335 in rear bumper cover
 Parking Aid Loudspeaker R169

 Left front parking aid display Y13
 Rear parking aid display Y15
Fault Finding".
sequence:
 Body
 Parking aid
 Functions
 Diagnostic test mode
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Parking Aid Button E266 , removing and installing
 Parking Aid Button E266 , removing and installing --> Switch in center of instrument panel, removing
and installing.
Front sensors for parking assistance, removing and installing
6 sensors are located in front bumper cover.
NOTE:  Removal and installation of sensors for parking assistance, front, is

performed in the same way for all sensors and is only described for one
sensor.
Fig. 484: Identifying Release Tool T10345

 Release tool T10345
Removing:
CAUTION: The sequence of removal of the sensors must be strictly followed.
Otherwise, the sensor may be damaged. If the force exerted on a sensor is

too large, hair cracks can develop which in turn can lead to sensor failure.
First remove the sensors from the brackets with the removal tool and then
disconnect the sensor connectors.
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Fig. 485: Removing/Installing Retaining Tabs With Release Tool T10345 & Remove Sensor With
Connector
 Disengage retaining tabs - arrows - with Release Tool T10345 and remove sensor with connector
connected from bumper cover.
NOTE:  Make sure that the sensor seal does not remain in bumper cover.
Fig. 486: Identifying Sensor Electrical Connector

Installing:
CAUTION: There is the risk of malfunction if an incorrect or damaged decoupling ring

is installed.
Replace damaged decoupling rings and make sure the correct decoupling
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ring is installed.
 If necessary, replace sensor seal (decoupling ring).
Fig. 487: Identifying Decoupling Ring

 Check whether correct seal (decoupling ring) is installed. A black silicone ring - 1 - must be installed.
NOTE:  Primarily, the decoupling ring has the function of decoupling the
vibrations between sensor diaphragm and sensor bracket. It also centers
the sensor diaphragm in the respective sensor bracket.
Fig. 488: Identifying Dimension Of Decoupling Ring

 Check the correct seating of the sensor. Dimension - a - must be evenly all around.
Rear sensors for parking assistance, removing and installing
6 sensors are located in rear bumper cover.
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NOTE:  Removal and installation of sensors for parking assistance, rear, is

performed in the same way for all sensors and is only described for one
sensor.
Fig. 489: Identifying Release Tool T10345

 Release tool T10345
Removing:
CAUTION: The sequence of removal of the sensors must be strictly followed.
Otherwise, the sensor may be damaged. If the force exerted on a sensor is

too large, hair cracks can develop which in turn can lead to sensor failure.
First remove the sensors from the brackets with the removal tool and then
disconnect the sensor connectors.
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Fig. 490: Locating Retaining Tabs And Sensor At Bumper Cover

 Disengage retaining tabs - arrows - with Release Tool T10345 and remove sensor with connector
connected from bumper cover.
NOTE:  Make sure that the sensor seal does not remain in bumper cover.
Fig. 491: Sensor For Parking Assistance Electrical Connection

Installing:
CAUTION: There is the risk of malfunction if an incorrect or damaged decoupling ring

is installed.
Replace damaged decoupling rings and make sure the correct decoupling
ring is installed.
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 If necessary, replace sensor seal (decoupling ring).
Fig. 492: Identifying Decoupling Ring

 Check whether correct seal (decoupling ring) is installed. A black silicone ring - 1 - must be installed.
NOTE:  Primarily, the decoupling ring has the function of decoupling the
vibrations between sensor diaphragm and sensor bracket. It also centers
the sensor diaphragm in the respective sensor bracket.
Fig. 493: Identifying Dimension Of Decoupling Ring

 Check the correct seating of the sensor. Dimension - a - must be evenly all around.
Left Front Parking Aid Display Y13 , removing and installing
Left Front Parking Aid Display Y13 is located above storage compartment in center of instrument cluster.

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adhesive tape.
Removing:
Fig. 494: Removing/Installing Instrument Cluster Cover

 Carefully pry off cover from instrument cluster - arrows -.
Fig. 495: Identifying Left Front Parking Aid Display Y13 From Instrument Cluster
 Pry out Left Front Parking Aid Display Y13 from instrument cluster - arrows -.
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Fig. 496: Identifying Left Front Parking Aid Display Y13 Electrical Connector
Installing:
Rear Parking Aid Display Y15 , removing and installing
Rear Parking Aid Display Y15 is installed in molded headliner above rear window.

adhesive tape.
Removing:
Fig. 497: Identifying Rear Parking Aid Display Y15 From Molded Headliner
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 Carefully pry out Rear Parking Aid Display Y15 from molded headliner - arrows -.
Fig. 498: Identifying Rear Parking Aid Display Y15 From Molded Headliner Electrical Connector
Installing:
Parking Aid Loudspeaker R169 , removing and installing
Parking Aid Loudspeaker R169 is located on bracket for relay carrier and Vehicle Electrical System Control
Module J519 in front left foot well.
 Remove foot well cover, drivers side --> 68 - INTERIOR EQUIPMENT .

 Remove relay carrier in front left foot well --> Relay carrier in front left foot well, removing and
installing.
Fig. 499: Identifying Parking Aid Loudspeaker R169 & Bracket

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 Pry Parking Aid Loudspeaker R169 - 1 - from bracket using a screwdriver - 2 -.
Fig. 500: Identifying Electrical Connection

Installing:
SIDE SCAN LANE CHANGE ASSISTANCE
General information
NOTE:  Before troubleshooting or servicing, the technicians must be familiar with

the function and operation of the Side Scan lane change assistance.
 For additional information, Operating instructions.
Side Scan lane change assistance supports the driver with the help of radar sensors in the rear bumper cover that
monitor the blind angle and traffic behind the vehicle. Displays that inform the driver in two levels if Side Scan
lane change assistance has detected a vehicle on that side and if it deems the vehicle critical for a lane change
are installed on the inner side of the exterior mirror housing. In the "Information stage" , the displays in the
exterior mirrors light up and inform the driver that Side Scan lane change assistance has detected a vehicle on
that side and deems it critical to a lane change. If the turn signal is activated during the information stage, lane
change assistance switches to the "warning stage" and respective display in the exterior mirror blinks rapidly
and brightly.
Side Scan lane change assistance is operated using the assistance systems button in the turn signal lever and the
instrument cluster display. While driving, important information is shown in the instrument cluster display.
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Side Scan lane change assistance is equipped with OBD that facilitates fault finding.
To check the complete Side Scan lane change assistance system, perform output diagnostic test mode --> Lane
Change Assistance Control Modules , output diagnostic test mode.
Side Scan lane change assistance components:
 Lane Change Assistance Control Module J769 with radar sensor behind bumper cover in rear of vehicle
 Lane Change Assistance Control Module 2 J770 with radar sensor behind bumper cover in rear of vehicle
 Lane Change Assistance Warning Lamp (in drivers exterior mirror) K233
 Lane Change Assistance Warning Lamp (in front passengers exterior mirror) K234
Lane Change Assistance Control Module With Radar Sensor , removing and installing
The left Lane Change Assistance Control Module J769 or right Lane Change Assistance Control Module 2 J770
is combined into one unit with the radar sensor for the respective side. The Lane Change Assistance Control
Modules are located at the left and right behind the bumper cover.
NOTE:  If both Lane Change Assistance Control Modules or only the left Lane
Change Assistance Control Module J769 (master) is replaced, the lane
change assistance system must be first coded --> Lane Change
Assistance Control Modules , coding and then calibrated --> Side Scan
lane change assistance, calibrating after completing the assembly work.
 If only the (right) Lane Change Assistance Control Module 2 J770 (slave) is
changed, the lane change assistance system only has to be calibrated -->
Side Scan lane change assistance, calibrating after completing the
assembly work.
Removing:
NOTE:  The following describes the removal and installation of the right Lane
Change Assistance Control Module 2 J770 , removal and installation of the
left Lane Change Assistance Control Module J769 is done in the same
way.
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Fig. 501: Removing/Installing Three Mounting Bolts & Lane Change Assistance Control Module From
Bracket

 Remove three mounting bolts - arrows - and remove Lane Change Assistance Control Module - 3 - from
bracket - 1 -.
Installing:
 After completing assembly work, calibrate Side Scan lane change assistance system --> Side Scan lane
change assistance, calibrating.
NOTE:  If both Lane Change Assistance Control Modules or only the left Lane
Change Assistance Control Module J769 (master) is replaced, the lane
change assistance system must be first coded --> Lane Change
Assistance Control Modules , coding and then calibrated --> Side Scan
lane change assistance, calibrating after completing the assembly work.
 If only the (right) Lane Change Assistance Control Module 2 J770 (slave) is
changed, the lane change assistance system only has to be calibrated -->
Side Scan lane change assistance, calibrating after completing the
assembly work.
Lane Change Assistance Warning Lamps in exterior mirror, removing and installing
Removal and installation of the Lane Change Assistance Warning Lamp (in drivers exterior mirror) K233 or
Lane Change Assistance Warning Lamp (in front passengers exterior mirror) (K234 is done in the same way
and is only described for one side in the following illustrations.
NOTE:  The brightness of the warning lights when operating depends on the
brightness of the surroundings and is controlled via the rain and light
sensor.
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Removing:
 Remove mirror glass --> 66 - EXTERIOR EQUIPMENT
Fig. 502: Exploded View Of Electrical Harness Connector & Retaining Tab

 Release retaining tab - arrow A - and press Lane Change Assistance Warning Lamp (in exterior mirror) -
2 - outward out of mirror housing - arrow B -.
Installing:
NOTE:  In the case of one or more faulty LEDs, the Lane Change Assistance
Warning Lamp (in exterior mirror) must be completely replaced.
CAUTION: Risk of slivers
The mirror glass can break
Wear protective gloves when carrying out this work
NOTE:  Make sure to press only in mirror center.
 Attach mirror glass at mirror adjusting unit and press on mirror glass.
Side Scan lane change assistance, calibrating
The left Lane Change Assistance Control Module J769 (master) or right Lane Change Assistance Control
Module 2 J770 (slave) is combined into one unit with the radar sensor for the respective side. They are located
behind the rear bumper cover and must be calibrated after:
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 Removal and installation of the bumper cover

 Removal and installation of one or both lane change assistance control modules
 Each time the installation location of a lane change assistance control module is changed
Before the calibration procedure can be performed with the Vehicle Diagnosis, Testing and Information System
VAS 5051B , considerable preparation work must be performed.
Measurement set-up
Fig. 503: Identifying Measurement Set-Up

1 - Volkswagen logo
 The laser point is aligned on the center of the Volkswagen logo
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2 - Wheel center sensor VAS 6350/1
 With wheel bolt adapter SW 16 and measuring paddle
3 - Catch bracket
 For mounting distance laser VAS 6350/2 for distance measurement

 Distance to wheel center sensors VAS 6350/1 on rear wheels: Dimension - a - = 1700 ± 2 mm.
4 - Water level
 On Calibration Device VAS 6350

 To check horizontal position of Calibration Device VAS 6350
5 - Calibration Device VAS 6350
6 - Plastic foot
 Qty. 3
 Adjustable in order to adjust horizontal position of Calibration Device VAS 6350
7 - Distance Laser VAS 6350/2
 For distance measurement

 Usage operating instructions
8 - Line Laser VAS 6350/3
 With "Laser eye protection"

 On Calibration Device VAS 6350
 Switching on and off operating instructions
9 - Measurement scale
 For positioning Lane Change Assistance Calibration Device VAS 6350/4

 Dimension to be adjusted measuring point on steel ruler = 773 mm
10 - Lane Change Assistance Calibration Device VAS 6350/4
 Is moved from right to left side of measuring field during calibration

 When installed correctly, vehicle electrical system voltage line must be connected at bottom left of
calibration device (as seen in direction of travel)
Preparatory work procedures for calibrating
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Before the calibration procedure can be performed with the Vehicle Diagnosis, Testing and Information System
VAS 5051B , considerable preparation work must be performed.
Requirements:
 Place vehicle on a solid, level surface

 Activate parking brake - vehicle must not move during measurement
 Place front wheels in straight-ahead position - steering wheel in 0 position
 On vehicles with air suspension, set vehicle height to middle position (display in instrument cluster
display)
 Remove sticker with metal foil from bumper cover if necessary

 No persons may be in the vehicle interior during the measurement
 Do not open and close the vehicle doors during calibration
Fig. 504: Identifying Vehicle Diagnosis, Testing And Information System VAS 5051B
 Vehicle Diagnostic, Testing and Information System VAS 5051B with diagnostic cable VAS 5051/5 A
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Fig. 505: Identifying Calibration Device VAS 6350

 Calibration Device VAS 6350
 Connect Vehicle Diagnosis, Testing and Information System VAS 5051B with Diagnostic Cable VAS
5051/5 A.
NOTE:  If an error message appears on the display , VAS 5051B operating

instructions.
 Switch on ignition.
Fig. 506: Identifying Wheel Pick-Ups On Wheel Mounting Bolts At Rear Wheels
 Secure three SW 19 wheel bolt adapters for wheel bolts on each Wheel Center Sensor VAS 6350/1.
 Insert measuring paddle on both wheel center sensors VAS 6350/1 and secure with lock nut.
 Place Wheel Center Sensor VAS 6350/1 on wheel bolts on both rear wheels.
 Wheel center sensor rotation center must be in wheel rotation center.
NOTE:  Place Wheel Center Sensor VAS 6350/1 on wheels so that "anti-theft wheel
bolts" are not connected with wheel center sensor.
 Adjust measuring paddle with aid of lock nuts so that they move freely just above the floor.
 The measuring paddles must move easily.

 The measuring paddles must be vertical.
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Fig. 507: Determining Distance Between Calibration Device VAS 6350 And Rear Wheels
 Position Calibration Device VAS 6350 at distance - a - from rear wheels.
 Dimension - a - = 1700 2 mm.
Fig. 508: Identifying Laser Display

 Switch distance laser VAS 6350/2 on with ON button.
Display on VAS 6350/2 :
 "- - - m"
NOTE:  Laser is switched on at same time.
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Fig. 509: Ensuring Laser Beam From Distance Laser VAS 6350/2 Hits Lower, Enlarged Part Of Paddle
 Hold the distance laser VAS 6350/2 - 2 - flush against the catch bracket, as shown in the illustration, for
the distance measurement.
 The distance laser VAS 6350/2 lie firmly against catch bracket.
 Ensure "laser beam" for distance measurement hits the lower enlarged portion of the measuring paddle - 1
-.
If this is not the case, measure paddle height must be corrected using lock nuts on Wheel Center Sensor VAS
6350/1.
Fig. 510: Identifying Display on VAS 6350/2

 Briefly press ON button for distance measurement.
Display on VAS 6350/2 :
 "1.700 m" (specified value: 1700 ± 2 mm).
 Repeat measurement procedure from left catch bracket to measurement paddle on left rear wheel.
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 The value read off for distance must be identical on both sides.
If both measured values are not the same, adjust Calibration Device VAS 6350 accordingly.
Fig. 511: Identifying Dimension

 Secure lane change assistance calibration device VAS 6350/4 at left rear of Calibration Device VAS 6350
mount.
calibration device (as seen in direction of travel).
 Dimension - a - = 850 mm (measured from upper edge of calibration device to workshop floor).
 The adjustment dimension is set with the measuring point - arrow - on the base of the calibration device
on the scale of the steel ruler - 1 -.
 Left setting = 773 mm (read on measurement scale - 1 -).
 Connect lane change assistance calibration device VAS 6350/4 to vehicle electrical system voltage.
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Fig. 512: Identifying Center Of The Indicator

 Using the bubble level (level indicator) - arrow - , bring the Calibration Device VAS 6350 into a
horizontal position by turning the plastic bases.
Fig. 513: Switching Laser VAS 6350/3 On & Calibration Device VAS 6350 On
 Put on "Laser eye protection".

 Switch Line Laser VAS 6350/3 on Calibration Device VAS 6350 on.
 Align the entire Calibration Device VAS 6350 so that the laser beam shines on the center of the vehicle
rear above the VW logo.
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 Check right and left distance between catch bracket on Calibration Device VAS 6350 and measuring
paddle - 1 - on wheel sensors again.
 Specified value: 1700 ± 2 mm
Lane Change Assistance Control Module, calibrating.
Lane Change Assistance Control Module J769/J770 , calibrating
NOTE:  Before the actual calibration procedure for the lane change assistance
control modules, the Calibration Device VAS 6350 must be set up as
described in chapter.
Fig. 515: Identifying Vehicle Diagnosis, Testing And Information System VAS 5051B
 Vehicle Diagnostic, Testing and Information System VAS 5051B with diagnostic cable VAS 5051/5 A
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The following should not occur during the calibration procedure:
 Vehicle doors must not be opened or closed.

 People should not sit in the vehicle.
 People should not go between the vehicle and the lane change assistance calibration device VAS 6350/4.
Procedure
Fig. 517: Identifying Assistance Calibration Device VAS 6350/4 Components

 Switch lane change assistance calibration device VAS 6350/4 on at power switch - 3 -.
 The green LED - 1 - must light up.
NOTE:  If the red LED - 2 - lights up: Check lane change assistance calibration
device VAS 6350/4.
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Fault Finding".
sequence:
 Body
 Lane change assistance
 Functions
 Calibration - lane change assistance
 Follow further instructions on display of VAS 5051B.
Fig. 518: Switching Lane Change Assistance Calibration Device VAS 6350/4 Off & Moving Device
During the course of the program, a request is made to switch the lane change assistance calibration device
VAS 6350/4 from the left to the right side of the Calibration Device VAS 6350.
 Switch lane change assistance calibration device VAS 6350/4 off and move device.
calibration device (as seen in direction of travel).
 Dimension - a - = 850 mm (measured from upper edge of calibration device to floor).
 Right setting = 773 mm (read on measurement scale - 1 -).
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Fig. 519: Identifying Assistance Calibration Device VAS 6350/4 Components

 Switch lane change assistance calibration device VAS 6350/4 on at power switch - 3 -.
 The green LED - 1 - must light up.
 Follow further instructions on display of VAS 5051B.
After successful lane change assistance calibration, switch the ignition off and disconnect the diagnostic
connector.
Lane Change Assistance Control Modules , output diagnostic test mode
Fault Finding".
sequence:
 Body
 Functions
 Output diagnostic test mode - lane change assistance
Lane Change Assistance Control Modules , coding
Microsoft
Fault Finding".
sequence:
 Body
 Functions
 Coding - lane change assistance
REARVIEW CAMERA SYSTEM
Rearview Camera System
NOTE:  Before troubleshooting or servicing, the technicians must be familiar with

the function and operation of the rearview camera system.
 For additional information, Operating instructions.
 When performing service work or fault-finding, use Vehicle Diagnosis,
Testing and Information System VAS 5051A or Vehicle Diagnosis and
Service System VAS 5052 in the function "Guided Fault Finding" , -->
Electrical Wiring Diagrams, Troubleshooting and Component Locations.
 When the battery is re-attached, remember to check the vehicle
accessories (radio, clock, electronic conveniences, etc.) according to the
article and/or the operators manual.
The rearview camera system assists the driver during back-up driving by providing the driver with an image of
the traffic situation behind the vehicle via the monitor of the radio/navigation system. The system is a vehicle
option and is only available in conjunction with the "electronic parking assistance" system and radio/navigation
system "RNS MFD 2".
The system switches itself on by selecting the reverse driving gear, even when radio/navigation system is
switched off.
The rearview camera system consists of the following components:
 Rearview Camera R189 ,

 Rearview Camera System Control Module J772 ,
 Radio/Navigation Display Control Module J503 ,
 And steering wheel with Steering Angle Sensor G85.
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NOTE:  It is not permitted to install an auxiliary license plate holder for vehicles
with rearview camera system because it would impair the function of the
rearview camera system. License plate lights may also be impaired.
Rearview camera system is equipped with On Board Diagnostic (OBD).
When performing fault-finding, use Vehicle Diagnosis, Testing and Information System VAS 5051A or Vehicle
Diagnosis and Service System VAS 5052 in the function "Guided Fault Finding".
Rearview camera, removing and installing
Fig. 520: Identifying Component Location Of Rearview Camera In Rear Lid

Component location of rearview camera in rear lid - arrow -
Rearview camera, removing from rear lid
Removing:
Before starting repair work, perform the following points:
In order to remove the camera, the lower tailgate trim must be removed first, --> 70 - INTERIOR TRIM .
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Fig. 521: Identifying Real Lid Cover

 Unclip cover - A - from rear lid.
Fig. 522: Identifying Securing Clips

 Push both securing clips - arrows - inward out of assembly holes.
Fig. 523: Pulling Out Both Wiring Harnesses From Rear Lid Interior So That Harness Connectors In
Both Wiring Harnesses Emerge
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 Pull out both wiring harnesses - arrows - from rear lid interior so that harness connectors in both wiring
harnesses emerge.
 Press locking mechanisms of harness connectors and disconnect them.
Fig. 524: Identifying Emergency Release Cable Bracket Nuts

 Remove both nuts on bracket for emergency release cable - arrows -.
Fig. 525: Removing/Installing Emergency Release Cable & Bracket

 Remove emergency release cable by moving gray plastic bracket in direction - A - and simultaneously
moving emergency release cable in direction - B - until both parts unhook from lock linkage and can be
removed.
 Press locking mechanism of harness connector and disconnect it.
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Fig. 526: Identifying Rearview Camera Holder Bolts

 Remove both bolts - arrows - on rearview camera holder.
Fig. 527: Removing/Installing Rearview Camera & Retainer

 While being careful of connected lines, remove rearview camera together with retainer in - direction of
arrow - from rear lid.
Remove rearview camera from holder.
Installing:
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Fig. 528: Identifying Wire Connection

Make sure that wire connection is routed as depicted in the illustration - arrow -.
 After installing, clean rearview camera optical lens using a lint-free cloth so that later a clean image is
ensured.
 Calibrate the system anew, --> Rearview camera system, calibrating.
Removing rearview camera from holder
Removing:
Fig. 529: Identifying Review Camera Holder Bolts

 Remove both bolts - arrows -.
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Fig. 530: Removing/Installing Retaining Bracket & Rearview Camera

 Remove retaining bracket in - direction of arrow - and pull rearview camera - A - out of holder.
 Guide wire connection of rearview camera out through opening in retaining bracket.
 Separate securing clip from harness connector.
Now the harness connector fits through opening in retaining bracket and both parts can be disconnected from
each other.
Installing:
Control module for rearview camera system, removing and installing
Control module is installed in luggage compartment behind right side wall trim.
Removing:
Before starting repair work, perform the following points:
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Fig. 531: Identifying Center Loading Floor In Luggage Compartment

 Remove center loading floor - A - in luggage compartment.

 Remove cover from lock carrier --> 70 - INTERIOR TRIM .
Fig. 532: Locating Tie Downs & Screw

 Remove tie-downs - arrows -.
Fig. 533: Locating Tie Downs & Screw

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 Remove screw - A - and remove right loading floor.

 Remove right D-pillar trim --> 70 - INTERIOR TRIM
Fig. 534: Identifying Screws & Interior Light

 Remove screws - A - and unclip interior light - B - from trim.
Fig. 535: Uncliping Trim from D-Pillar

 Unclip trim from D-pillar in - direction of arrow -.
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Fig. 536: Removing/Installing Trim At Side Window

 Unclip trim at side window in - direction of arrow -.
Fig. 537: Identifying Swing Trim & Camera System

 Carefully swing trim - 1 - as far in - direction of arrow - so that control module for rearview camera
system - A - is accessible.
Fig. 538: Removing/Installing Control Module

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 Press both locking mechanisms - arrows - and remove control module for rearview camera system.
NOTE:  It is possible that the control module is also secured with Velcro on the
bottom. Then, carefully detach control module from base plate.
Fig. 539: Removing/Installing Harness Connector From Control Module

 Press locking mechanism - A - and fold over the bracket in direction - B -. Then disconnect harness
connector from control module.
Fig. 540: Removing/Installing Control Module

 Press locking mechanism - A - and pull harness connector out of control module in direction - B -.
Installing:
If necessary, replace Velcro strips - arrows - on bottom of control module.

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Only if the control module has been replaced:
 Calibrate the system anew, --> Rearview camera system, calibrating.
Rearview camera system, calibrating
After performing service work on the vehicle, it may be necessary to calibrate the rearview camera system
anew. In detail, this is the case after:
 Removing and installing rearview camera

 Replacing the control module for rearview camera system
 After repair work performed on rear lid following an accident
 After a vehicle alignment
 After performing a repair at front or rear axle
Extensive preparatory work must be completed before the appropriate calibrating procedure can be performed
using diagnostic operation system VAS 5051A or vehicle diagnosis and service information system VAS 5052.
This is described in the following.

Preparatory work procedures for calibrating:
Vehicle must stand on a firm and level surface to perform the calibration. No persons may be in the
vehicle interior during the measurement. Vehicle must not be moved during the measurement, opening
and closing of vehicle doors is to be avoided, suspension should not be loaded and should be locked in
position to avoid movement during calibration.
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NOTE:  The standing height of vehicle is measured vertically from fender or lower
edge of side panel to center of wheel. Specified values can be found in
Vehicle Diagnosis, Testing and Information System VAS 5051A.
Connect Vehicle Diagnosis, Testing and Information System VAS 5051A --> Vehicle Diagnostic, Testing and
 Bring the Steering Angle Sensor G85 into 0-position (wheels straight ahead).
Overview of the assembled measuring device:
Fig. 542: Identifying VAS 6350/1 Sensor Components

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3 - Right-side angle bracket for mounting measuring unit for distance measurement
4 - Plastic foot
 Total of three on under side of measuring device

 Adjustable, for aligning horizontal position of measuring device
5 - Line Laser VAS 6350/3
 Switching on and off operating instructions
6 - Distance Laser VAS 6350/2
 Notes on operation, operating instructions
7 - Fluid level on measuring device
 For checking horizontal position of measuring device
8 - Left-side angle bracket for mounting measuring unit for distance measurement
9 - Calibration Device VAS 6350/4
 Distance to rear wheels 1.20 m-1.70 m - dimension A -
 Check which hole circle the rims have.

 Install the wheel pick-ups which fit the Touareg: For this purpose, secure three adapters for wheel
mounting bolts for Touareg on the hole circle with designation "120" or "130" on each wheel pick-up.
 Attach paddles to both wheel pick-ups VAS 6350/1 and secure them with clamping screw.
Fig. 543: Identifying Wheel Pick-Ups On Wheel Mounting Bolts At Rear Wheels
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 Place Wheel Center Sensor VAS 6350/1 on wheel bolts on rear wheels. When doing this, the wheel pick-
ups are positioned by the O-rings in the adapters and held in place.
NOTE:  Attach wheel pick-ups on to wheels so that any installed anti-theft wheel
mounting bolts are not connected to the wheel pick-ups.
 Set the paddles via the clamping screw so that they are free to move just above the ground.
Make sure paddles move easily.
 Position Calibration Device VAS 6350/4 behind vehicle at a distance of 1.20 m - -1.70 m from the rear
wheels as depicted in the overview - dimension A -.
Fig. 544: Identifying Center Of The Indicator

 Bring Calibration Device VAS 6350/4 to a horizontal position. To do so, twist plastic feet under
calibration device so that air bubble in spirit level is located exactly in the center of the indicator - arrow
-.
Fig. 545: Aligning Calibration Device

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 Switch on the laser on the calibration device - 1 - and align the entire calibration device so that laser beam
strikes on center of vehicle rear end above the VW logo.
Fig. 546: Identifying Laser Display

 Switch on the Distance Laser VAS 6350/2 for distance measurement with the ON button. The following
display appears and laser switches itself on:
 Hold distance laser for distance measurement - 2 - flush into angle bracket on one side of calibration
device as shown in the illustration, distance laser must make contact firmly on angle bracket when doing
this.
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 Ensure the laser beam from the distance laser for distance measurement contacts the paddle - 1 - at the
lower, enlarged part.
If this is not the case, paddles must be corrected accordingly via the clamping screws on the wheel pick-ups.
Fig. 549: Identifying Display Readout

 Hold the distance laser for distance measurement firmly by the hand in the angle bracket on the
measuring device while the laser beam can be seen on the paddle. Now press the ON button briefly for
the distance measurement. When doing this, the following display appears on screen:
The distance measurement is specified on the display in "meters".
 Note the value read off.

 Repeat measuring procedure in the same manner for the other rear wheel on the other side of the
calibration device.
The value read off for distance must be identical on both sides. If the value is not identical, align the calibration
device only as long until the values on both sides are identical.
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When aligning the calibration device, make sure the distance laser beam still strikes the center above the VW
logo and indicator of fluid-level remains centered. If necessary, make further corrections accordingly.
The dimension for distance that was measured must be entered during calibration into the Vehicle Diagnostic,
Testing and Information System VAS 5051A or Diagnostic Operation System VAS 5052 in "millimeters".
Rearview camera system, calibrating.
Rearview camera system, calibrating
 Select "Guided Functions" in Vehicle Diagnosis, Testing and Information System VAS 5051A or Vehicle
Diagnosis and Service System VAS 5052.
or
Select "Guided Fault Finding" in Vehicle Diagnosis, Testing and Information System VAS 5051A or Vehicle
Diagnosis and Service System VAS 5052.
 In the "Vehicle selection" menu, enter the corresponding data for the vehicle and the following menu
items one after another.
 Rear system
 Functions
 Rearview camera system, calibrating
From here, you will be directed by the Vehicle Diagnosis, Testing and Information System VAS 5051A or the
Vehicle Diagnosis and Service Information System VAS 5052 during the calibrating procedure.
TIGHTENING TORQUES: LIGHTS, SWITCHES - EXTERIOR
Tightening Torques: Headlamp

Front headlamp mount 5 Nm
Rear headlamp mount 5 Nm
Tightening Torques: Fog lamps

Headlamp mounting bolts 1.5 Nm
Tightening Torques: Taillamp assembly in side panel
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Mounting bolts for taillamp assembly in side panel 4 Nm
Mounting bolts for adjustable taillamp assembly 4 Nm
carrier
Tightening Torques: Taillamp assembly in rear lid

Mounting nuts of taillamp assembly in rear lid 4 Nm
Tightening Torques: Steering column switch

Hex socket head bolt beneath steering column 1.5 Nm
switch
Tightening Torques: Rear window opening

Mounting nuts of lock bracket and wiper shaft with 8 Nm
crank
Hex nut for Rear Window Opening Button 12 Nm
96 - LIGHTS, SWITCHES - INTERIOR, ANTI-THEFT

INTERIOR LIGHTS AND SWITCHES
Interior monitoring and vehicle inclination deactivation switch, vehicles through 11/06, removing and installing
Interior Monitoring Deactivation Switch E267 and Deactivate Vehicle Inclination Sensor Button E360 ,
through 11/06, removing and installing

adhesive tape.
NOTE:  To remove the Interior Monitoring Deactivation Switch E267 and

Deactivate Vehicle Inclination Sensor Button E360 , anti-theft warning
system must be deactivated.
 The Interior Monitoring Deactivation Switch E267 and Deactivate Vehicle
Inclination Sensor Button E360 comprise one component.
 Interior Monitoring Deactivation Switch E267 and Deactivate Vehicle
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Inclination Sensor Button E360 are located in B-pillar trim on drivers side.
Removing:
Fig. 550: Interior Monitoring Deactivation Switch E267 And Deactivate Vehicle Inclination Sensor
Button E360 Pried Out Using Removal Wedge VAS 3409 Or A Screwdriver
 Carefully pry out Interior Monitoring Deactivation Switch E267 and Deactivate Vehicle Inclination
Sensor Button E360 using a screwdriver.
Fig. 551: Interior Monitoring Deactivation Switch E267 And Deactivate Vehicle Inclination Sensor
Button E360 Connector
 Release and disconnect the connector - arrow -.
Installing:
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Interior monitoring and vehicle inclination deactivation switch, vehicles from 12/06, removing and installing
Interior Monitoring Deactivation Switch E267 and Deactivate Vehicle Inclination Sensor Button E360 ,
from 12/06, removing and installing
From 12/06 (model year 2007), the "interior monitoring deactivation" and "deactivate vehicle inclination
sensor" have been combined into one button with one symbol.
Fig. 552: Identifying Trim Removal Wedge 3409

 Trim removal wedge VAS 3409
CAUTION: When removing and installing components in a visible area (switches,

covers, trim, etc.), mask off the areas at which a prying tool (trim removal
wedge VAS 3409 , screwdriver) will be positioned, using commercially
available adhesive tape.
NOTE:  To remove the Interior Monitoring Deactivation Switch E267 and

Deactivate Vehicle Inclination Sensor Button E360 , anti-theft warning
system must be deactivated.
 The Interior Monitoring Deactivation Switch E267 and Deactivate Vehicle
Inclination Sensor Button E360 comprise one component.
 Interior Monitoring Deactivation Switch E267 and Deactivate Vehicle
Inclination Sensor Button E360 are located in B-pillar trim on drivers side.
Removing:
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Fig. 553: Identifying Button

 Carefully pry up button - 1 - using Trim Removal Wedge VAS 3409 or screwdriver.
Fig. 554: Removing/Installing Button Connector

 Release and disconnect connector - arrow - and remove it from button.
Installing:
Foot well lamps
Foot well lamps:
 Left Front Footwell Illumination L151

 Right Front Footwell Illumination L152
 Left Rear Footwell Illumination L106
 Right Rear Footwell Illumination L107
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NOTE:  The front foot well lights are located in trim beneath instrument cluster.
 The rear foot well lights are installed at rear in center of front seats.
 Only glass socket lamps 12 V, 3 W must be installed, even when glass
socket lamps 12 V, 5 W were previously installed.
Footwell lights, removing and installing

adhesive tape.
NOTE:  The front foot well lights are located in trim beneath instrument cluster.
 The rear foot well lights are installed at rear in center of front seats.
 Removal and installation for all foot well lights is performed in the same
way and is only described for one light.
Removing:
Fig. 555: Identifying Light

 Carefully pry out foot well lights using a screwdriver.

 Release the connector and disconnect it.
Bulb, replacing:
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Fig. 556: Identifying Retaining Tabs & Heat Shield

 Disengage retaining tabs - 1 - and remove heat shield - 2 - from diffusion lens of foot well light.
Fig. 557: Prying Bulb From Socket

 Carefully pry bulb from socket.
NOTE:  Only glass socket lamps 12 V, 3 W must be installed, even when glass
socket lamps 12 V, 5 W were previously installed.
 Replace bulb (12 V, 3 W).
Installing:
Foot well lamps, checking
Foot well lamps (Left Front Footwell Illumination L151 , Right Front Footwell Illumination L152 , Left Rear
Footwell Illumination L106 and Right Rear Footwell Illumination L107) can be checked via output Diagnostic
Microsoft
ENGINE COMPARTMENT - LIGHTS AND SWITCHES
Engine Compartment Light W27 , removing and installing

adhesive tape.
Removing:
Fig. 558: Prying Out Light Using Screwdriver

 Carefully pry out light using a screwdriver.
Fig. 559: Identifying Engine compartment Light W27 Lamp Socket

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 Remove lamp socket - arrow - from Engine Compartment Light W27.
Bulb, replacing:
Fig. 560: Removing/Installing Bulb

 Carefully remove bulb from socket.

Installing:
Front Hood Switch F266 , removing and installing
NOTE:  Front Hood Switch F266 is integrated in lid lock and cannot be replaced
separately.
 The entire lid lock must always be replaced if Front Hood Switch F266 is
malfunctioning.
 Remove hood lock --> 55 - HOOD, LIDS .
INSTRUMENT PANEL - LIGHTS AND SWITCHES
Light Switch E1 , removing and installing
The following components are integrated with Light Switch E1 :
 Rear Fog Lamp Button E314

 Fog Lamp Button E315
 Headlamp Switch Illumination L9
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Removing:
 Turn rotating handle of Light switch E1 to position "0".
Fig. 561: Pushing In Rotating Handle Of Light Switch E1 & Turning Slightly Toward Right
 Push in rotating handle of Light switch E1 - arrow 1 - and turn slightly toward right - arrow 2 -.
 Hold rotary handle in this position and remove Light switch E1 on rotary handle from instrument cluster -
arrow 3 -.
Fig. 562: Removing/Installing Rotating Handle Connector

Installing:
 Connect electrical connector.
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Fig. 563: Installing Light Switch

 Hold Light switch E1 firmly and press in rotary handle of Light switch E1 - 1 - and turn slightly toward
right - 2 -.
 Hold rotary knob in this position and insert Light Switch E1 into instrument panel - 3 -.
 Turn rotary handle to position "0" , release and engage switch.
Headlamp Adjuster E102 and Instrument Panel Light Dimmer Switch E20 , removing and installing
NOTE:  Headlamp Adjuster E102 and Instrument Panel Light Dimmer Switch E20
comprise one component.
Removing:
 Remove instrument cluster trim on drivers side --> 70 - INTERIOR TRIM .
Fig. 564: Removing/Installing Instrument Cluster Connector

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Fig. 565: Removing/Installing Headlamp Adjuster E102

 Compress side retaining straps at Headlamp Adjuster E102 and Instrument Panel Light Dimmer Switch
E20 - arrows - so that retaining tabs disengage.
 Remove Headlamp Adjuster E102 and Instrument Panel Light Dimmer Switch E20 - A - toward rear out
of installation frame in instrument cluster trim.
Installing:
Front Passengers Airbag Disabled Indicator Lamp K145 , removing and installing
Removal and installation of the following components is performed in the same way and is only described for
one component.
 Drivers Heated Seat Adjuster E94

 Front Passengers Heated Seat Adjuster E95
 Emergency Flasher Switch E3
 Parking Aid Button E266
 Front Passengers Airbag Disabled Indicator Lamp K145
 Removing and installing --> Switch in center of instrument panel, removing and installing.
Glove Compartment Light W6 , removing and installing

adhesive tape.
Removing:
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Fig. 566: Prying Out Glove Compartment Light W6

 Carefully pry out Glove Compartment Light W6 using a screwdriver.

Bulb, replacing:

 Disengage retaining tabs - 1 - and remove heat shield - 2 - from diffusion lens of Glove Compartment
Light W6.
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Installing:
Glove Compartment Light Switch E26 , removing and installing
Fig. 569: Identifying Switch, Holder, & Instrument Panel

NOTE:  The illustration shows Glove Compartment Light Switch E26 - 1 - with
instrument cluster removed. The instrument panel does not need to be
removed in order to remove and install the switch.
 Glove Compartment Light Switch E26 - 1 - can be reached starting from
foot well and can be unclipped.
 The wire to Glove Compartment Light Switch E26 - 1 - is long enough to
pull the Glove Compartment Light Switch E26 with wire connected into
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foot well and then to disconnect the harness connector.
Removing:
 Unclip Glove Compartment Light Switch E26 - 1 - with connected wire from bracket - A arrows -.
 Pull Glove Compartment Light Switch E26 - 1 - downward behind instrument cluster - arrow B - and
disconnect connector.
Installing:
Switch in center of instrument panel, removing and installing
Removal and installation of the following components is performed in the same way and is only described for
one component.
 Drivers Heated Seat Adjuster E94

 Front Passengers Heated Seat Adjuster E95
 Emergency Flasher Switch E3
 Parking Aid Button E266
 Front Passengers Airbag Disabled Indicator Lamp K145

adhesive tape.
Removing:
 In vehicles without radio/navigation system or radio, pry cover (radio cut-out) from mounts --> 70 -
INTERIOR TRIM .
 If necessary, remove radio --> 91 RADIO, TELEPHONE, NAVIGATION, TRIP COMPUTER .
 If necessary, remove radio/navigation system --> 91 RADIO, TELEPHONE, NAVIGATION, TRIP
COMPUTER .
Microsoft
Fig. 570: Removing/Installing Hazard Switch

 Press switch out of installation frame from behind.
Fig. 571: Removing/Installing Hazard Switch Connector

Installing:
FRONT DOORS - LIGHTS AND SWITCHES
Drivers door switch module, removing and installing
The following components are integrated in driver side switch module:
 Left Front Window Regulator Switch E40

 Drivers Left Rear Window Regulator Switch E53
 Drivers Right Rear Window Regulator Switch E55
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 Drivers Right Front Window Regulator Switch E81
 Child Safety Button E318

 Push Button Light L76
 Drivers Interior Locking Button E308

adhesive tape.
Removing:
 Remove door trim on driver side --> 70 - INTERIOR TRIM .
Fig. 572: Removing/Installing mounting bolt & air channel

 Remove mounting bolt - 1 - and remove air channel - 2 -.
Fig. 573: Removing/Installing mounting bolts & switch module out of door trim
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 Remove mounting bolts - arrows - and remove switch module out of door trim.
Installing:
Drivers Interior Locking Indicator Lamp K174 and Front Passengers Central Locking -SAFE- Indicator Lamp K204
Drivers Interior Locking Indicator Lamp K174 and Front Passengers Central Locking -SAFE- Indicator Lamp K204 , removing
and installing

adhesive tape.
NOTE:  Removal and installation of Drivers Interior Locking Indicator Lamp K174
and Front Passengers Central Locking -SAFE- Indicator Lamp K204 is
performed in the same way and is only described for one indicator lamp.
Removing:
 Remove door trim.
Removal at driver door: --> 70 - INTERIOR TRIM .
Removal at front passenger door: --> 70 - INTERIOR TRIM .
Fig. 574: Central Locking -SAFE- Indicator Lamp K133

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 Unclip Drivers Interior Locking Indicator Lamp K174 or Front Passengers Central Locking -SAFE-
Indicator Lamp K204 - 1 - out of door trim by compressing retaining tabs - arrows -.
Fig. 575: Central Locking -SAFE- Indicator Lamp K133 And Harness Connector
 Disconnect connector - 1 - of Drivers Interior Locking Indicator Lamp K174 or Front Passengers Central
Locking -SAFE- Indicator Lamp K204 - 2 -.
Installing:
Drivers Interior Locking Indicator Lamp K174 and Front Passengers Central Locking -SAFE- Indicator Lamp K204 , checking
Drivers Interior Locking Indicator Lamp K174 and Front Passengers Central Locking -SAFE- Indicator Lamp
K204 can be checked via output Diagnostic Test Mode (DTM) of Comfort System Central Control Module
J393.
Window Regulator Switch (in RF door) E107 , removing and installing

adhesive tape.
NOTE:  Removal and installation of Window Regulator Switch (in RF door) E107 ,
Left Rear Window Switch, (In LR Door) E52 and Right Rear Window Switch,
(In RR Door) E54 is performed in the same way and is only described for
one switch.
 Power Window Switch Light L53 , which cannot be replaced separately, is
integrated in Window Regulator Switch (in RF door) E107.
integrated in Left Rear Window Switch, (In LR Door) E52.
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integrated in Right Rear Window Switch, (In RR Door) E54.
Removing:
Removal at rear doors: --> 70 - INTERIOR TRIM .
Fig. 576: Identifying Connector


 Disengage retaining tabs - arrows - and remove switch together with installation frame from door trim.
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Fig. 578: Disengage Retaining Tabs & Remove Switch From Installation Frame
 Disengage retaining tabs - arrows - and remove switch from installation frame.
Installing:
Fuel Filler/Rear Lid Remote Unlocking Button E463
Fuel Filler/Rear Lid Remote Unlocking Button E463 for vehicles --> 01.03, removing and installing

adhesive tape.
Removing:
Fig. 579: Removing/Installing Installation Frame Of Fuel Filler/Rear Lid Remote Unlocking Button E463
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In & Remove It
 Pull installation frame of Fuel Filler/Rear Lid Remote Unlocking Button E463 in - direction of arrow -
and remove it.
Fig. 580: Removing/Installing Electrical Connections

 Unlock and disconnect electrical connections - arrows -.
Fig. 581: Removing/Installing Retaining Tabs & Remove Button From Installation Frame
 Disengage retaining tabs - arrows - and remove button from installation frame.
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Fig. 582: Removing/Installing Retaining Tabs & Remove Button From Installation Frame
 Disengage retaining tabs - arrows - and remove button from installation frame.
Installing:
Fuel Filler/Rear Lid Remote Unlocking Button E463 for vehicles 01.03 --> , removing and installing
CAUTION:  By reason of the cable length for connector, door trim must be
removed in order to be able to disconnect the connector without
destroying it.
 When removing and installing components in visible area (switches,
covers, trim, etc.), cover by taping the areas at which a prying tool
(plastic wedge, screwdriver) will be positioned using commercially
available adhesive tape.
Removing:
 Remove door trim --> 70 - INTERIOR TRIM .
Microsoft
Fig. 583: Identifying Fuel Filler/Rear Lid Remote & Connector

 Disconnect connector - 1 - from Fuel Filler/Rear Lid Remote Unlocking Button E463 - 2 -.
Fig. 584: Removing/Installing Installation Frame Of Fuel Filler/Rear Lid Remote Unlocking Button E463
In & Remove It
 Pull installation frame of Fuel Filler/Rear Lid Remote Unlocking Button E463 in - direction of arrow -
and remove it.
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Fig. 585: Identifying Fuel Filler/Rear Lid Remote Unlocking Button E463 Retaining Tabs
 Disengage retaining tabs - arrows - and remove Fuel Filler/Rear Lid Remote Unlocking Button E463 - 1
- from installation frame - 2 -.
Installing:
Front Passengers Interior Locking Button E309 , removing and installing

adhesive tape.
NOTE:  Removal and installation of Front Passengers Interior Locking Button

E309 , Left Rear Interior Locking Button E310 and Right Rear Interior
Locking Button E311 is performed in the same way and is only described
for one switch.
 Switch Illumination Lamp L156 , which cannot be replaced separately, is
integrated in Front Passengers Interior Locking Button E309.
integrated in Left Rear Interior Locking Button E310.
integrated in Right Rear Interior Locking Button E311.
Removing:
Removal at rear doors: --> 70 - INTERIOR TRIM .
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Fig. 586: Identifying Connector

Fig. 587: Disengaging/Engaging Retaining Tabs & Removing/Installing Button

 Disengage retaining tabs - arrows - and remove button.
Installing:
Drivers Inside Door Handle Illumination L146 and Front Passengers Inside Door Handle Illumination L147
Drivers Inside Door Handle Illumination L146 and Front Passengers Inside Door Handle Illumination L147 , removing and
installing

adhesive tape.
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NOTE:  Removal and installation of Drivers Inside Door Handle Illumination L146 ,
Front Passengers Inside Door Handle Illumination L147 , Left Rear Inside
Door Handle Illumination L133 and Right Rear Inside Door Handle
Illumination L134 is performed in the same way and is only described for
one light.
Removing:
Removal at driver door: --> 70 - INTERIOR TRIM .
Fig. 588: Removing/Installing Connector

Fig. 589: Disengaging/Engaging Tabs & Removing/Installing LED With Diffusion Lens
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 Disengage retaining tabs - arrows - and remove LED with diffusion lens.
Fig. 590: Turn & Pull Led Out Of Diffusion Lens

 Turn and pull LED - 1 - out of diffusion lens - 2 -.
Installing:
Drivers Inside Door Handle Illumination L146 and Front Passengers Inside Door Handle Illumination L147 , checking
Drivers Inside Door Handle Illumination L146 and Front Passengers Inside Door Handle Illumination L147 can
be checked via output Diagnostic Test Mode (DTM) of Comfort System Central Control Module J393.
Left Front Entry Light W31 and Right Front Entry Light W32
NOTE:  Removal and installation for all entry lights is performed in the same way
and is only described for one light.
Entry lights:
 Left Front Entry Light W31

 Right Front Entry Light W32
 Left Rear Entry Light W33
 Right Rear Entry Light W34
Left Front Entry Light W31 and Right Front Entry Light W32 , removing and installing

adhesive tape.
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Removing:
Fig. 591: Identifying Retaining Tabs Of Bulb


Bulb, replacing:

 Disengage retaining tabs - 1 - and remove heat shield - 2 - from diffusion lens of light.
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Installing:
Left Front Entry Light W31 and Right Front Entry Light W32 , checking
Left Front Entry Light W31 and Right Front Entry Light W32 can be checked via output Diagnostic Test Mode
Drivers Door Warning Light W30 and Front Passengers Door Warning Light W36
Drivers Door Warning Light W30 and Front Passengers Door Warning Light W36 , removing and installing

adhesive tape.
NOTE:  Removal and installation for all door warning lights is performed in the
same way and is only described for one light.
Door warning lights:
 Drivers Door Warning Light W30

 Front Passengers Door Warning Light W36
 Left rear door warning light W37
 Right rear door warning light W38
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Removing:
Fig. 594: Prying Out Light Using Screwdriver


Bulb, replacing:

 Disengage retaining tabs - 1 - and remove heat shield - 2 - from diffusion lens of light.
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Installing:
Drivers Door Warning Light W30 and Front Passengers Door Warning Light W36 , checking
Drivers Door Warning Light W30 and Front Passengers Door Warning Light W36 can be checked via output
Diagnostic Test Mode (DTM) Comfort System Central Control Module J393.
Front Door Locks - Electrical Components, overview
Depending on equipment level, the following components are integrated with the drivers door lock:
 Drivers Door Contact Switch F2

 Drivers Door Central Locking Lock Unit F220
 Drivers Door Central Locking System Motor V56
 Drivers Door Central Locking (Safe) Motor V161
 Drivers Door Central Locking Switch F59
Depending on equipment level, the following components are integrated with the front passengers door
lock:
 Front Passengers Door Contact Switch F3

 Front Passengers Door Central Locking Lock Unit F221
 Front Passengers Door Central Locking System Motor V57
 Front Passengers Central Locking (Safe) Motor V162
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 Front Passengers Door Central Locking System Switch F114
NOTE:  The components listed above cannot be replaced separately.
In the event of front door lock component malfunctions:
 Replace the respective door lock --> 57 - FRONT DOORS, CENTRAL LOCKING SYSTEM .
REAR DOORS - LIGHTS AND SWITCHES
Left Rear Interior Locking Button E310 and Right Rear Interior Locking Button E311 , removing and installing
NOTE:  Removal and installation of Front Passengers Interior Locking Button

E309 , Left Rear Interior Locking Button E310 and Right Rear Interior
Locking Button E311 is performed in the same way and is only described
for one switch --> Front Passengers Interior Locking Button E309 ,
integrated in Front Passengers Interior Locking Button E309.
integrated in Left Rear Interior Locking Button E310.
integrated in Right Rear Interior Locking Button E311.
Left Rear Window Switch, (In LR Door) E52 and Right Rear Window Switch, (In RR Door) E54 , removing and
installing
NOTE:  Removal and installation of Window Regulator Switch (in RF door) E107 ,
Left Rear Window Switch, (In LR Door) E52 and Right Rear Window Switch,
(In RR Door) E54 is performed in the same way and is only described for
one switch --> Window Regulator Switch (in RF door) E107 , removing and
installing.
integrated in Window Regulator Switch (in RF door) E107.
integrated in Left Rear Window Switch, (In LR Door) E52.
integrated in Right Rear Window Switch, (In RR Door) E54.
Ashtray Light L15 , removing and installing
Ashtray Illumination L15 is a component of the ashtray insert in door trim and cannot be replaced separately.
 In the event of repairs, replace the complete ashtray insert --> 70 - INTERIOR TRIM .
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Left Rear Inside Door Handle Illumination L133 and Right Rear Inside Door Handle Illumination L134
Left Rear Inside Door Handle Illumination L133 and Right Rear Inside Door Handle Illumination L134 , removing and installing
NOTE:  Removal and installation of Drivers Inside Door Handle Illumination L146 ,
Front Passengers Inside Door Handle Illumination L147 , Left Rear Inside
Door Handle Illumination L133 and Right Rear Inside Door Handle
Illumination L134 is performed in the same way and is only described for
one light.
Left Rear Inside Door Handle Illumination L133 and Right Rear Inside Door Handle Illumination L134 , checking
Left Rear Inside Door Handle Illumination L133 and Right Rear Inside Door Handle Illumination L134 can be
checked via output Diagnostic Test Mode (DTM) of Comfort System Central Control Module J393.
Left Rear Entry Light W33 and Right Rear Entry Light W34
Left Rear Entry Light W33 and Right Rear Entry Light W34 , removing and installing
Left Rear Entry Light W33 and Right Rear Entry Light W34 , checking
Left Rear Entry Light W33 and Right Rear Entry Light W34 can be checked via output Diagnostic Test Mode
Left Rear Door Warning Light W37 and Right Rear Door Warning Light W38
Left Rear Door Warning Light W37 and Right Rear Door Warning Light W38 , removing and installing
NOTE:  Removal and installation for all door warning lights is performed in the
same way and is only described for one light.
Left Rear Door Warning Light W37 and Right Rear Door Warning Light W38 , checking
Left Rear Door Warning Light W37 and Right Rear Door Warning Light W38 can be checked via output
Diagnostic Test Mode (DTM) Comfort System Central Control Module J393.
Rear Door Locks - Electrical Components, overview
Depending on equipment level, the following components are integrated with the left rear door lock:
 Left Rear Door Contact Switch F10

 Left Rear Central Locking Lock Unit F222
 Left Rear Central Locking (Lock) Motor V214
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 Left Rear Central Locking (Safe) Motor V163
 Left Rear Central Locking Switch F346
Depending on equipment level, the following components are integrated with the right rear door lock:
 Right Rear Door Contact Switch F11

 Right Rear Central Locking Lock Unit F223
 Right Rear Central Locking (Lock) Motor V215
 Right Rear Central Locking (Safe) Motor V164
 Right Rear Central Locking Switch F347
NOTE:  The components listed above cannot be replaced separately.
In the event of rear door lock component malfunctions:
 Replace the respective door lock --> 58 - REAR DOORS .
LUGGAGE COMPARTMENT - LIGHTS AND SWITCHES
Luggage Compartment Light W3
Luggage Compartment Light W3 , removing and installing

adhesive tape.
NOTE:  Two luggage compartment lights are installed. Removal and installation is
the same for both luggage compartment lights and is only described for
one of the lights.
Removing:
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Fig. 597: Prying Out Luggage compartment Light W3 Using Screwdriver

 Carefully pry out Luggage Compartment Light W3 using a screwdriver.
Fig. 598: Identifying Luggage Compartment Light Connector

Bulb, replacing:
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Fig. 599: Identifying Contact Plate & Light Lamp

 Push contact plate - 1 - of Luggage Compartment Light W3 in - direction of arrow - and remove light
lamp - 2 - out of socket.
Installing:
Luggage Compartment Light W3 , checking
Luggage Compartment Light W3 can be checked via output Diagnostic Test Mode (DTM) of Comfort System
Rear Lid Courtesy Lamp W51
Rear Lid Courtesy Lamp W51 , removing and installing

adhesive tape.
Removing:
Fig. 600: Prying Out Rear Lid Courtesy Lamp W51 Using Screwdriver
 Carefully pry out Rear Lid Courtesy Lamp W51 using a screwdriver.
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Fig. 601: Removing/Installing Rear Light Courtesy Lamp Connector

Bulb, replacing:
Fig. 602: Identifying Retaining Tab & Reflector Plate

 Release retaining tab - 1 - and remove reflector plate - 2 -.
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Fig. 603: Identifying Contact Plate & Rear Lid Courtesy Lamp W51
 Push contact plate - 1 - of Rear Lid Courtesy Lamp W51 in - direction of arrow - and remove lamp - 2 -
out of socket.
Installing:
Rear Lid Courtesy Lamp W51 , checking
Rear Lid Courtesy Lamp W51 can be checked via output Diagnostic Test Mode (DTM) of Comfort System
Rear Lid Lock Unit F256
Rear Lid Lock Unit F256 , removing and installing
Rear Lid Lock Unit F256 is integrated in rear lid lock and cannot be replaced separately.
In the event the Rear Lid Lock Unit F256 malfunctions, the complete rear lid lock must be replaced.
 Replacing rear lid lock --> 55 - HOOD, LIDS .
Converter with Socket, 12V, 230V U13 , removing and installing
Fig. 604: Identifying Socket

Socket 12V, 230V - 1 - is installed in side wall trim on right side in luggage compartment. Converter is installed
on a retainer on right rear wheel housing and is joined permanently to the socket.
CAUTION:  In the Converter with Socket, 12V, 230V U13 housing are capacitors
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which maybe charged with a residual voltage.

 There is a danger of electric shock.
 The housing of Converter with Socket, 12V, 230V U13 must not be
opened under any circumstances.

 Trim removal wedge 3409
NOTE:  When removing and installing components in a visible area (switches,

wedge 3409 , screwdriver) will be positioned, using commercially available
adhesive tape.
 No repairs may be performed on the harness connector, on the wires and
the 230V-socket.
 If there is a fault at harness connector, at wires, at 230V-socket or in the
converter, the complete unit must always be replaced.
Removing:
 Remove right side panel trim in luggage compartment --> 70 - INTERIOR TRIM .
Microsoft
Fig. 606: Identifying Retaining Tabs, Socket, & Socket Mount

 Push the two retaining tabs - 3 - outward in - direction of arrow - and pull socket - 2 - toward rear out of
socket mount - 1 - in side trim.
NOTE:  Socket mount is joined permanently to the side trim.
Fig. 607: Identifying Mounting Bolt, Converter & Harness Connector

 Disengage and disconnect harness connector - 1 - at converter - 2 -.

 Remove mounting bolt - 3 - and remove converter upward from bracket.
Installing:
 When inserting converter, make sure that guide rails on converter sit correctly on bracket and converter
fits securely after tightening the mounting bolt - 3 -.
Converter with Socket, 12V, 230V U13 , removing and installing
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Fig. 608: Identifying Socket

Socket 12V, 230V - 1 - is installed in side wall trim on right side in luggage compartment. Converter is installed
on a retainer on right rear wheel housing and is joined permanently to the socket.
CAUTION:  In the Converter with Socket, 12V, 230V U13 housing are capacitors
which maybe charged with a residual voltage.
 There is a danger of electric shock.
 The housing of Converter with Socket, 12V, 230V U13 must not be
opened under any circumstances.

 Trim removal wedge 3409
NOTE:  When removing and installing components in a visible area (switches,

wedge 3409 , screwdriver) will be positioned, using commercially available
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adhesive tape.
 No repairs may be performed on the harness connector, on the wires and
the 230V-socket.
 If there is a fault at harness connector, at wires, at 230V-socket or in the
converter, the complete unit must always be replaced.
Removing:
Fig. 610: Identifying Retaining Tabs, Socket, & Socket Mount

 Push the two retaining tabs - 3 - outward in - direction of arrow - and pull socket - 2 - toward rear out of
socket mount - 1 - in side trim.
NOTE:  Socket mount is joined permanently to the side trim.
Fig. 611: Identifying Mounting Bolt, Converter & Harness Connector

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 Disengage and disconnect harness connector - 1 - at converter - 2 -.

 Remove mounting bolt - 3 - and remove converter upward from bracket.
Installing:
 When inserting converter, make sure that guide rails on converter sit correctly on bracket and converter
fits securely after tightening the mounting bolt - 3 -.
HEADLINER - LIGHTS AND SWITCHES
Front interior light W1 , removing and installing

adhesive tape.
Removing:
Fig. 612: Identifying Diffusion Lens

 Carefully pry diffusion lens for Front Interior Light W1 out of console in molded headliner - arrow -.
Bulb, replacing:
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Fig. 613: Identifying Contact Plate & Front Interior Light W1

 Push contact plate - 1 - of Front Interior Light W1 in direction of - arrow - and remove bulb - 2 - from
socket.
Installing:
Front Passengers Map/Reading Light W13 and Left Front Reading Light W19 , removing and installing

adhesive tape.
Removing:
Fig. 614: Identifying Diffusion Lens

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 Carefully pry diffusion lens out of console in molded headliner - arrow -.
Fig. 615: Identifying Front Passengers Map/Reading Light W13 Connector

Bulb, replacing:
NOTE:  Replacement of lamps for both reading lights is performed in the same
way and is only described for one light.
Fig. 616: Turning Light Socket In Direction Of Arrow & Remove

 Turn light socket in direction of - arrow - and remove.
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Fig. 617: Glass Socket Lamp Removed Out Of Socket


Installing:
Button module for front interior reading light, removing and installing
The button module consists of the following components:
 Front interior lamp button E326

 Drivers reading light button E457
 Front Passengers Reading Light Button E458

adhesive tape.
NOTE:  Buttons cannot be replaced separately. If repairs are necessary, the entire
button module must be replaced.
Removing:
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Fig. 618: Identifying Molded Headliner Console Cover

 Carefully pry cover out of console in molded headliner - arrow -.
Fig. 619: Identifying Button Of Interior Reading Light

 Carefully pry button module for interior reading light out of console in molded headliner - arrow -.
Fig. 620: Identifying Interior Reading Light Connector

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 Unclip both microphones of hands-free equipment.
Fig. 621: Removing/Installing Button Module

 Disengage retaining tabs - arrows - and remove button module from frame.
Installing:
Sunroof Switch E8

adhesive tape.
NOTE:  Sunroof Switch Light L65 is located beneath Sunroof switch E8.
Removing:
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Fig. 622: Removing/Installing Sunroof Switch E8

 Disengage retaining tabs - arrows - and remove Sunroof switch E8 with trim out of console in molded
headliner.
Fig. 623: Identifying Sunroof Switch Connectors

 Disconnect connectors - arrows -.
Fig. 624: Identifying Sunroof Switch Retaining Tabs

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 Disengage retaining tabs - arrows -.
Fig. 625: Removing/Installing Sunroof Switch Harness Connector

 Disconnect harness connector - arrow - and remove Sunroof switch E8 from trim.
Installing:
Sunroof Switch Light L65 , removing and installing
Removing:
 Remove Sunroof switch E8 --> Sunroof Switch E8.
Fig. 626: Removing/Installing Sunroof Switch Light Mounting Bolts

 Remove mounting bolts - arrows - and remove Sunroof Switch Light L65 from trim.
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Installing:
Left Rear Reading Light W11 and Right Rear Reading Light W12 , removing and installing
NOTE:  Removal and installation for both rear reading lights is performed in the
same way and is only described for one reading light.
Removing:
Fig. 627: Identifying Fold Up Cover

 Fold up cover - arrow -.
Fig. 628: Identifying Reading Light Mounting Bolt

 Remove mounting bolt - arrow - and remove reading light.
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Fig. 629: Removing/Installing Reading Light Connector

Bulb, replacing:
Fig. 630: Removing/Installing Lamp Carrier With Switches From Diffusion Lens
 Disengage retaining tab - arrow - and remove lamp carrier with switches from diffusion lens.
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Fig. 631: Identifying Lamp Carrier With Switches & Light Bulb

Installing:
Roof Display Unit J702 , removing and installing
 Roof Display Unit J702 , removing and installing --> 91 RADIO, TELEPHONE, NAVIGATION,
TRIP COMPUTER .
Garage Door Opener Control Head E284 , removing and installing

adhesive tape.
The control head consists of the following components:
 Garage Door Opener Button 1 E392

 Garage Door Opener Indicator Lamp K179
 Push Button Illumination L76
Removing:
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Fig. 632: Identifying Control Head

 Carefully pry control head out of console in molded headliner - arrow -.
Fig. 633: Removing/Installing Control Head

 Disengage retaining tabs - arrows - and remove control head from frame.
Installing:
Garage Door Opener Control Head E284 , removing and installing

adhesive tape.
The control head consists of the following components:
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 Garage Door Opener Indicator Lamp K179
 Push Button Illumination L76
Removing:
Fig. 634: Identifying Control Head

 Carefully pry control head out of console in molded headliner - arrow -.
Fig. 635: Removing/Installing Control Head

 Disengage retaining tabs - arrows - and remove control head from frame.
Installing:
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CENTER CONSOLE - LIGHTS AND SWITCHES
Center Armrest Illumination L157 , removing and installing

adhesive tape.
Removing:
Fig. 636: Prying Out Center Armrest Illumination L157 Using Screwdriver
 Carefully pry out Center Armrest Illumination L157 using a screwdriver.

Bulb, replacing:
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 Disengage retaining tabs - 1 - and remove heat shield - 2 - from diffusion lens of Center Armrest
Illumination L157.


Installing:
Storage Compartment Illumination Switch F335 , removing and installing
Storage Compartment Illumination Switch F335 is located in center console behind rear air vents.
Removing:
 Remove rear air vents in center console --> 68 - INTERIOR EQUIPMENT .
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Fig. 639: Identifying Storage Compartment Illumination Switch F335 Retaining Tab
 Disengage retaining tab - arrow - and remove Storage Compartment Illumination Switch F335.
Installing:
Module for outside mirror adjustment, removing and installing
The module for outside mirror adjustment (depending on equipment) consists of the following components:
 Mirror Adjustment Switch E43

 Mirror Selector Switch E48
 Switch for outside mirror heating E231
 Mirror Folding Switch E263
 Mirror Adjusting Switch Light L78
Removing:
 Remove selector lever cover --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING .
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 Disengage retaining tabs - arrows - and remove module for outside mirror adjustment out of cover.
Installing:
Level Control System Control Head E281 , removing and installing
The Level Control System Control Head E281 is located in the right of the center console behind the switch
cover.
Removing:
 Remove shifter selector cover --> 68 - INTERIOR EQUIPMENT .
Fig. 641: Identifying Level Control System Control Head E281 Retaining Tabs
 Press the three retaining tabs - arrows - together and remove Level Control System Control Head E281
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from switch cover.
Installing:
Suspension adjustment module, removing and installing
The suspension adjustment module is located in the center console in the center behind the switch cover.
Depending on equipment, the suspension adjustment module contains the following components:
 Dampening adjustment button E387

 Level control button E388
 Stabilizer Decoupling Button E484
NOTE:  The suspension adjustment module cannot be diassembled further. If

there is a defect, the suspension adjustment module must be completely
replaced.
 The suspension adjustment control module is removed and installed the
same way regardless of equipment versions.
Removing:
 Remove shifter selector cover --> 68 - INTERIOR EQUIPMENT .
Fig. 642: Removing/Installing Suspension Adjustment Module

 Release retaining tabs - arrows - with a suitable screwdriver and remove suspension adjustment module -
1 - from switch cover.
Installing:
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Transfer Case Operating Unit E473
The Transfer Case Operating Unit E473 is located in the left of the center console, behind the switch cover.
The Transfer Case Operating Unit E473 is removed and installed the same way as the Level Control System
Control Head E281 --> Level Control System Control Head E281 , removing and installing.
HORN
High Tone Horn H2 and Low Tone Horn H7 , removing and installing
NOTE:  High Tone Horn H2 and Low Tone Horn H7 are activated in parallel by
Vehicle Electrical System Control Module J519.
 Removal and installation procedure for both horns is the same.
Removing:
 Turn off the ignition and all electrical components.
Fig. 643: Identifying Air Guide

 Remove noise insulation --> 63 - BUMPERS .
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Fig. 644: Identifying Signal Horn Mounting Bolt & Harness Connector
 Unclip air guide - 1 - in - direction of arrow -.

 Disconnect harness connector - A -.
 Remove mounting bolt - B - and remove signal horn.
Installing:
 Install in reverse order of removal.
High Tone Horn H2 and Low Tone Horn H7 , checking
Signal horns (High Tone Horn H2 and Low Tone Horn H7) can be checked via output Diagnostic Test Mode
(DTM) of Vehicle Electrical System Control Module J519.
IMMOBILIZER FROM 12/06
General information
The Touareg from 12/06 is equipped with a fourth generation immobilizer with on-line connection and
download. The chief integral component of the fourth generation immobilizer is a central database, in which all
anti-theft relevant data of participating control modules is stored. It is not possible to adapt participating control
modules to the immobilizer without an on-line connection to this database.
Fazit system test --> Fazit system test.
 There is no PIN inquiry of immobilizer components by fax and previously performed enablings of the
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components.
 All components participating on the immobilizer must be adapted on-line.
 All vehicle keys (subsequently ordered keys as well) are already pre-coded to a specific vehicle from the
factory and can only be adapted to this vehicle.
 Additional vehicle keys must be ordered specifying the respective Vehicle Identification Number (VIN).
 It is no longer possible to perform adaptation on components originating from other sales group brands in
Volkswagen vehicles.
Immobilizer components:
 Anti-Theft Immobilizer Control Module J362 --> Anti-Theft Immobilizer Control Module J362
 Access/Start Control Module J518 --> Access/Start Control Module J518
 Engine Control Module (ECM) J623 --> 23 - DIESEL FUEL INJECTION
 Electronic Steering Column Lock Control Module J764 --> Electronic steering column lock (ELV)
 Ignition Key
Functions of Anti-Theft Immobilizer Control Module J362
 Communication of all components participating on immobilizer with each other.

 Data encryption between participating control modules.
The immobilizer is equipped with On Board Diagnostic (OBD) capabilities which aids in troubleshooting.
The "Guided Fault Finding" function is to be used for troubleshooting of one of the systems described as in
chapter "Vehicle Diagnosis, Testing and Information System" --> Vehicle Diagnostic, Testing and
Anti-Theft Immobilizer Control Module J362
The Anti-Theft Immobilizer Control Module J362 is integrated in the Access/Start Control Module J518.
If the immobilizer control module is faulty, the Access/Start Control Module J518 must be replaced.
Adapting Anti-Theft Immobilizer Control Module J362
Anti-Theft Immobilizer Control Module J362 , adapting or.
Access/Start Control Module J518
Access/Start Control Module , replacing
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Fault Finding".
sequence:
 Body
 Body Assembly Work
 Functions
 Access/Start Control module, replacing
Access/Start Control Module , new
Fault Finding".
sequence:
 Body
 Immobilizer with download
 Functions
 New Access/Start Control Module
Access/Start Control Module , used
Fault Finding".
sequence:
 Body
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 Functions
 Used Access/Start Control Module
Access/Start Control Module , coding
Fault Finding".
sequence:
 Body
 Functions
 Control module, coding
Access/Start Control Module , output Diagnostic Test Mode (DTM)
Fault Finding".
sequence:
 Body
 Functions
 Diagnostic test mode
Electronic steering column lock (ELV)
Electronic steering column lock (ELV), adapting
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Fault Finding".
sequence:
 Body
 Functions
 ELV, reactivating
Engine control module (ECM) J623
After installing a new or used engine control module (ECM), the ECM must always be adapted.
Engine Control Module (ECM) J623
Fault Finding".
sequence:
 Body
 Functions
 Engine Control Module (ECM), replacing
Immobilizer, new identity
All required steps necessary for new installation of all immobilizer components are performed by this program.
New identity immobilizer with new access/start control module and new engine control module (ECM)
New identity immobilizer with new access/start control module and new engine control module (ECM)
Microsoft
Fault Finding".
sequence:
 Body
 Functions
 New identity with new FBS and ECM
New identity immobilizer with used access/start control module and used engine control module (ECM)
New identity immobilizer with used access/start control module and used engine control module (ECM)
Fault Finding".
sequence:
 Body
 Functions
 New identity with old FBS and ECM
Ignition Key
All vehicle keys (subsequently ordered keys as well) are already pre-coded to a specific vehicle from the factory
and can only be adapted to this vehicle. Additional vehicle keys must be ordered specifying the respective
Vehicle Identification Number (VIN) and then the new key must be adapted to the Engine Control Module
(ECM) J362.
Ignition key, adapting
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Fault Finding".
sequence:
 Body
 Functions
 Key, adapting
Adapting ignition key
Fault Finding".
sequence:
 Body
 Functions
 Ignition key adaptation
Fazit system test
The following steps will be performed by this test program:
 System test for on-line connection

 Test of user authorization
 Test of correct wire connection to Volkswagen database
The requirements for this is the on-line connection (network connection) of the tester
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Fault Finding".
sequence:
 Body
 Functions
 FAZIT on-line test
ANTI-THEFT ALARM SYSTEM
Anti-Theft Alarm System
Owners Manual
Anti-theft alarm system functions are integrated in Comfort System Central Control Module J393.
The most important information for activating and deactivating is provided by Access/Start Control Module
J518. Communication occurs via Comfort CAN-Bus.
Anti-theft alarm system is equipped with On Board Diagnostics (OBD) which assists troubleshooting.
NOTE:  After anti-theft alarm system has triggered, the alarm source, which is
stored in Comfort System Central Control Module J393 , can be checked.
Anti-theft Alarm System, activating and deactivating
NOTE:  If the vehicle was delivered from the factory with an Anti Theft Warning
System (ATWS) and a trailer hitch, a trailer can be integrated into the
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switched on ATWS --> Trailer, integrating in vehicle Anti Theft Warning

System.
Activating anti-theft alarm system:
Anti-theft warning system is automatically switched on by locking the vehicle. Anti-theft alarm system is then
activated immediately.
NOTE:  So that anti-theft alarm system does not trigger unnecessary alarms, close
all windows and doors before locking the vehicle.
Anti-theft alarm system, deactivating:
 Anti-theft alarm system is deactivated when the vehicle is unlocked via the unlock button on radio-
frequency remote control, or
 When vehicle is opened via Keyless Access, or
 When the ignition is switched on.
Unlocking vehicle mechanically (emergency opening)
 Unlock vehicle at drivers door.
Anti-theft alarm system remains activated, however no alarm is triggered.
 Switch on ignition within 15 seconds.
NOTE:  If the ignition is not switched on after 15 seconds the alarm is triggered.
By switching on the ignition, the electronic immobilizer recognizes a valid vehicle key and deactivates the anti-
theft alarm system.
Trailer, integrating in vehicle Anti Theft Warning System
If the vehicle was delivered from the factory with an Anti Theft Warning System (ATWS) and a trailer hitch, a
trailer can be integrated into the switched on ATWS.
Activating anti-theft alarm system:
 Insert trailer connector completely into vehicle trailer socket.

 Lock vehicle.
Anti-theft alarm system is then activated immediately. Trailer is now integrated in the ATWS.
NOTE:  An alarm is triggered as soon as the electrical connection to the trailer is

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interrupted with the vehicle locked.
Anti-theft alarm system, deactivating:
 Anti-theft alarm system is deactivated when the vehicle is unlocked via the unlock button on radio-
frequency remote control, or
 When vehicle is opened via Keyless Access, or
 When the ignition is switched on.
Unlocking vehicle mechanically (emergency opening)
 Unlock vehicle at drivers door.
Anti-theft alarm system remains activated, however no alarm is triggered.
 Switch on ignition within 15 seconds.
NOTE:  If the ignition is not switched on after 15 seconds the alarm is triggered.
By switching on the ignition, the electronic immobilizer recognizes a valid vehicle key and deactivates the anti-
theft alarm system.
Interior Monitoring Deactivation Switch E267 and Deactivate Vehicle Inclination Sensor Button E360
 Interior Monitoring Deactivation Switch E267 and Deactivate Vehicle Inclination Sensor Button E360 ,
removing and installing --> Interior monitoring and vehicle inclination deactivation switch, vehicles
through 11/06, removing and installing.
Interior Monitoring Sensor G273 , removing and installing
Interior Monitoring Sensor G273 is located in vicinity of roof module in molded headliner.

adhesive tape.
Removing:
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Fig. 645: Removing/Installing Molded Headliner Console Panel

 Carefully pry panel out of console in molded headliner - arrow -.
Fig. 646: Identifying Sensor Panel Retaining Tabs

 Disengage retaining tabs - arrows - and remove sensor from panel.

 Remove console in molded headliner --> 68 - INTERIOR EQUIPMENT .
Fig. 647: Disengaging Retaining Tabs & Removing Sensors From Panel
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 Disengage retaining tabs - arrows - and remove sensors from panel.

 Disconnect harness connector - 1 - and unclip sensor - 2 - from console.
Fig. 648: Identifying Console Sensor Harness Connector

 Unclip wires - 3 -.
Installing:
Vehicle Inclination Sensor G384 , removing and installing
NOTE:  To remove the Vehicle Inclination Sensor G384 , anti-theft warning system
must be deactivated --> Anti-theft Alarm System, activating and
deactivating.
Removing:
 Remove right side panel trim in luggage compartment --> 70 - INTERIOR TRIM
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Fig. 649: Identifying Vehicle Inclination Sensor Mounting bolts & Connector
 Disengage connector - 2 - and disconnect it from Vehicle Inclination Sensor G384.

 Remove mounting bolts - 1 - and remove Vehicle Inclination Sensor G384 upward out of bracket.
Installing:
Alarm Horn H12 (Back-up horn)
Alarm Horn H12 (Back-up horn) is located at left in plenum chamber, beneath E-Box.
Alarm Horn H12 (Back-up horn), removing and installing

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NOTE:  To remove the Alarm Horn H12 (Back-up horn), anti-theft warning system
must be deactivated --> Anti-theft Alarm System, activating and
deactivating.
Removing:
 Remove E-Box in plenum chamber at left --> Electronics box in left plenum chamber, removing and
installing.
Fig. 651: Identifying Alarm Horn Connector Components

Fig. 652: Identifying Alarm Horn H12 & Connector

 Disengage connector - 2 - and disconnect it from Alarm Horn H12 - 1 -.
Installing:

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Fig. 653: Identifying Alarm Horn Connector Components

NOTE:  If self-locking mounting nut - 3 - has been loosened in order to remove

bracket - 2 - , it must be replaced.
 Tighten all mounting bolts and nuts to specified tightening torque --> Tightening Torques: Alarm Horn
H12.
Alarm Horn H12 (Back-up horn), checking
Alarm Horn H12 (Back-up horn), can be checked via output Diagnostic Test Mode (DTM) of Comfort System
TIGHTENING TORQUES: LIGHTS, LAMPS, SWITCHES - INTERIOR
Tightening Torques: Alarm Horn H12

Self-locking mounting nut 5 Nm
Bolt 23 Nm
97 - WIRING
Vehicle Diagnostic, Testing and Information Systems
FUSE PANELS
Fuse Panels
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Fuse panel, removing and installing
NOTE:  In Touareg, there are two fuse holders installed, located at left and right on
instrument cluster.
 The illustration depicts work sequence "removing left fuse holder". Work
procedure for removing right fuse holder is identical.
Removing:


 Remove left side cover of instrument cluster --> 68 - INTERIOR EQUIPMENT .
Fig. 654: Removing/Installing Fuse Holder

 Remove both mounting bolts - arrows - and remove fuse holder - 1 - toward inside.
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Installing:
Back-up fuse box, removing and installing
The back-up fuse box is located under drivers seat next to the battery.
Removing:
Fig. 655: Identifying Back Up Fuse Box Components

 Remove mounting bolt - 1 - and pull off air vent - 2 - upward.

 Release - arrow - cover - 3 - of back-up fuse box and remove it upward.
NOTE:  If necessary, mark the equipment dependent allocation of individual wires

to connection points in back-up fuse box.
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Fig. 656: Identifying Back Up Fuse Box Mounting Nuts

 Loosen threaded connections and remove all wires from back-up fuse box connections.
 Unscrew mounting nuts (10 mm) - arrows - and remove back-up fuse box upward from vehicle.
Installing:
RELAY CARRIER
Relay carrier
Relay carrier in front left foot well, removing and installing
Removing:


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Fig. 657: Identifying Brake Pedal Switch Connector & Bracket

 Disconnect harness connector - 1 - at brake pedal switch.

 Loosen bolt at left - arrow - and at right (not shown) at bracket - 2 - of brake pedal switch.
 Remove bracket - 2 - of brake pedal switch out of vehicle.
Fig. 658: Identifying Front Relay Carrier

 Press retaining tabs - arrows - together and remove front relay carrier - 1 - with connected wires out of
bracket.
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Fig. 659: Removing/Installing Rear Relay Carrier

 Press retaining tabs - arrows - together and remove rear relay carrier - 1 - with connected wires out of
bracket.
Installing:
ELECTRONICS BOXES
Electronics Boxes
Electronics box in left plenum chamber, removing and installing
Removing:


 Remove drivers side wiper arm
 Remove front passengers side wiper arm
 Remove plenum chamber cover.
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Fig. 660: Removing/Installing E-Box Cover

 Remove mounting bolts - arrows - and remove E-Box cover.
Fig. 661: Identifying Housing Gasket & Multi-Pin Harness Connector

NOTE:  The number of multi-pin harness connectors - 2 - can deviate from the
illustration depending on vehicle equipment.
 Disconnect multi-pin harness connectors - 2 - and remove housing gasket - 1 - upward out of E-Box.
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Fig. 662: Identifying E-Box Components

NOTE:  The number of multi-pin harness connectors - 3 - and number of threaded

connections - 1 - can deviate from the illustration depending on vehicle
equipment.
 Loosen threaded connections - 1 - of supply wires and remove them from connecting pins.
 Unclip connector - 2 - from E-Box.
 Disconnect multi-pin harness connectors - 3 - and remove housing gasket - 4 - upward out of E-Box.
 Remove mounting bolts - arrows - from upper section of E-Box.
Fig. 663: Removing/Installing E-Box Mounting Bolts

 Remove upper section of E-Box upward.

 Unclip lower section of E-Box from vehicle.
Installing:
Install in reverse order of removal, observing the following:
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Fig. 664: Identifying E-Box Securing Rubbers

 Insert securing rubbers - 1 - into lower section of E-Box.
Fig. 665: Identifying E-Box Securing Rubbers On Pins

 Clip lower section of E-Box with securing rubbers on pins - arrows - on vehicle.
NOTE:  Sleeve seals for wires must be inserted into guides of E-Box.
 Wires must not be pinched when assembling upper and lower sections of
E-Box.
CONTROL MODULES
Vehicle Electrical System Control Module J519
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Fig. 666: Vehicle Electrical System Control Module J519

Vehicle Electrical System Control Module J519 - arrow - is located under instrument cluster, at left.
Vehicle Electrical System Control Module J519 has the following tasks in the vehicle:
 Electric load management

 Parking light
 Low beam headlamp
 Running light
 Turn signal (not in outside mirror)

 High beam headlamp
 Auxiliary high beam headlamp
 Fog lamps
 Foot well lamps

 Dimming, instrument illumination
 Indicator light for emergency flasher
 Headlamp washer system relay
 Fuel Pump (FP) supply

 Horn
 Dual washer pump
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 Interior light
 Voltage supply for Rain/Light sensor
Some of the functions listed above can be adapted:
NOTE:  "Tap signaling" , "comfort-flashing" , or "highway signaling" means that

turn signals are activated multiple times (1-5 times) when turn signal lever
is tapped once (signal cycles).
 Adapting signal cycles for "tap signaling"
 Adapting "activation times of headlamp washer system"
 Adapting "shut-off priority of electrical components"
Vehicle Electrical System Control Module J519 is equipped with On Board Diagnostics (OBD) which assists
troubleshooting.
Vehicle Electrical System Control Module J519 must be coded under the following conditions:
 Changes were made to vehicle equipment.

 One particular functionality is to be changed.
 Vehicle Electrical System Control Module J519 is to be replaced.
 Code Vehicle Electrical System Control Module J519.
Vehicle Electrical System Control Module J519 , removing and installing
NOTE:  If control module is being replaced, first perform work procedure.
Removing:
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Fig. 667: Identifying Vehicle Electrical System Control Module J519 & Harness Connectors
NOTE:  The number of multi-pin harness connectors - 1 - at Vehicle Electrical

System Control Module J519 can deviate from the illustration depending
on vehicle equipment.
 Release locking mechanisms of multi-pin harness connectors - arrows - and disconnect multi-pin harness
connectors - 1 - from Vehicle Electrical System Control Module J519 - 2 -.
 Remove Vehicle Electrical System Control Module J519 - 2 - with wires connected to rear side out of
bracket.
Fig. 668: Identifying Vehicle Electrical System Control Module & Multi-Pin Harness Connectors
 Release locking mechanisms of multi-pin harness connectors - arrows - and disconnect multi-pin harness
connectors - 1 - from Vehicle Electrical System Control Module - 2 -.
 Remove Vehicle Electrical System Control Module J519 from vehicle.
Installing:
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Vehicle Electrical System Control Module J519 , coding
Vehicle Electrical System Control Module J519 must be coded under the following conditions:
 Changes were made to vehicle equipment.

 One particular functionality is to be changed.
 Vehicle Electrical System Control Module J519 must be replaced.
Vehicle Electrical System Control Module J519 , coding:
Fault Finding".
sequence:
 Body
 Vehicle electrical system control module
 Functions of Vehicle Electrical System Control Module

 Coding Vehicle Electrical System Control Module
Output Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module J519
The following components of Vehicle Electrical System Control Module can be checked via output Diagnostic
Test Mode (DTM):
 Right Low Beam Headlamp M31 , for vehicles with gas-discharge lamps High intensity discharge lamp
L14
 Right High Beam Headlamp M32 , for vehicles with gas-discharge lamps Right Headlamp Reflector
Adjustment Solenoid N396
 Left Low Beam Headlamp M29 , for vehicles with gas-discharge lamps High intensity gas discharge
lamp L13
 Left High Beam Headlamp M30 , for vehicles with gas-discharge lamps Left Headlamp Reflector
Adjustment Solenoid N395
 Left Parking Light M1

 Right Parking Light M3
 Left Front Turn Signal Light M5 and Left Rear Turn Signal Light M6
 Right Front Turn Signal Light M7 and Right Rear Turn Signal Light M8
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 Left Front Fog Light L22 and Right Front Fog Light L23
 Only in vehicles with gas-discharge lamps Right High Beam Headlamp M32 and Left High Beam
Headlamp M30
 Headlamp Washer Relay J39 and Headlamp Washer Pump V11
 Indicator light for emergency flasher system K6
 High Tone Horn H2 and Low Tone Horn H7

 Left Front Footwell Illumination L151 , Right Front Footwell Illumination L152 , Left Rear Footwell
Illumination L106 and Right Rear Footwell Illumination L107
 Windshield and Rear Window Washer Pump V59
Fault Finding".
sequence:
 Body

 Output Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module
Signal cycles for "tap signaling" , adapting
NOTE:  "Tap signaling" , "comfort-flashing" , or "highway signaling" means that

turn signals are activated multiple times (1-5 times) when turn signal lever
is tapped once (signal cycles).
With this adaptation, there is the opportunity to set the signal cycles (1-5) of the "tap signaling" function.
Fault Finding".
sequence:
 Body
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 Adapting signal cycles for tap signaling
Adapting "activation time of headlamp washer system"
Firstly, the delay time up to activation of Headlamp Washer Pump V11 can be set; secondly, the activation time
of Headlamp Washer Pump V11 can be adapted automatically.
Fault Finding".
sequence:
 Body

 Adapting activation time of headlamp washer system
"Shut-off priority of electrical components" , adapting
With this function, there is the opportunity to read out and reset the maximum reached shut-off priority.
For each shut-off of a consumer, a counter in Vehicle Electrical System Control Module J519 counts up,
maximum value is 14.
Consumer shut-off sequence:
1. RPM increase (voltage less than 12.7 V) - at further decrease and short fall 12.2 V
2. PTC heating element to 75%
3. Reduction of heat performance to 50%
5. Seat heater and ventilation off
6. Front window shut-off
8. Wiper rest position heater off
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9. Mirror heater off

10. PTC Heating element off
11. Steering wheel heater off
12. Rear window heater off
13. RPM increase, 2nd stage
14. A/C system off
Fault Finding".
sequence:
 Body

 Adapting shut-off priority
Data Bus On Board Diagnostic Interface J533
Data Bus On Board Diagnostic Interface J533 is integrated in instrument cluster --> Instrument cluster.
Comfort System Central Control Module J393
Microsoft
Fig. 669: Identifying Comfort System Central Control Module J393 Components
Comfort System Central Control Module J393 - arrow A - is located in luggage compartment, at right on wheel
housing.
Comfort System Central Control Module J393 performs the following tasks in the vehicle:
 Sunroof control (issues enabling)

 Window regulator control (issues enabling)
 Central locking system control
 Anti-theft warning system control
 Radio receiver
 Rear lid closing
 Comfort operation
Some of the functions listed above can be adapted.
NOTE:  After installing a new Comfort System Central Control Module J393 , it
must be coded.
 After anti-theft alarm system has triggered, the alarm source, which is
stored in Comfort System Central Control Module J393 , can be checked.
troubleshooting.
Comfort System Central Control Module J393 , removing and installing
NOTE:  After installing a new Comfort System Central Control Module J393 , it
must be coded.
Microsoft
 Removing and installing Comfort System Central Control Module J393 --> 57 - FRONT DOORS,
CENTRAL LOCKING SYSTEM .
Comfort System Central Control Module J393 , output Diagnostic Test Mode (DTM)
 Interior Monitoring Off Indicator Lamp K162 in Interior Monitoring Deactivation Switch E267
 Vehicle Inclination Sensor Indicator Lamp K188 in Deactivate Vehicle Inclination Sensor Button E360
 Alarm Horn H12 (for anti-theft warning system)
 Signal sunroof open
 Signal sunroof close

 Rear window release
 Rear lid release
 Activation of rear wiper interval
 Activation of rear wiper wiper/washer function

 Driver door illumination, Drivers Interior Locking Indicator Lamp K174 , Drivers Inside Door Handle
Illumination L146 , Door warning light, driver side W30 , Left Front Entry Light W31 , Drivers Entry
Lamp (in outside mirror) W52 and Left Mirror Turn Signal Lamp L131
 Front passenger door illumination, Front Passengers Central Locking -SAFE- Indicator Lamp K204 ,
Front Passengers Inside Door Handle Illumination L147 , Door warning light, passenger side W36 , Right
Front Entry Light W32 , Front Passengers Entry Lamp (in outside mirror) W53 and Right Mirror Turn
Signal Lamp L132
 Left rear door illumination, Left Rear Door Warning Light W37 , Left Rear Entry Light W33 and Left
Rear Inside Door Handle Illumination L133
 Right rear door illumination, Right Rear Door Warning Light W38 , Right Rear Entry Light W34 and
Right Rear Inside Door Handle Illumination L134
 Central locking for driver door
 Central locking for front passenger door
 Central locking for left rear door
 Central locking for right rear door

 Left Brake/Tail Light M21 , Right Brake/Tail Light M22 , Left Tail Light Lamp 2 M49 and Right Tail
Light Lamp 2 M50
 High-mount Brake Light M25 , Left Brake/Tail Light M21 , Right Brake/Tail Light M22
 Left Rear Fog Light L46 and Right Rear Fog Light L47
 Left License Plate Light X4 and Right License Plate Light X5 , Left Back-Up Light M16 and Right Back-
Up Light M17 , Luggage Compartment Light W3 , Rear Lid Courtesy Lamp W51
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 Rear window heater

 Driver side mirror functions (heater, folding-in)
 Passenger side mirror functions (heater, folding-in)
NOTE:  Above system/component checks depend on market version and installed

equipment.
Fault Finding".
sequence:
 Body
 Comfort System Central Control Module
 Functions
 Comfort System Central Control Module -J393-, output Diagnostic Test Mode (DTM)
Comfort System Central Control Module J393 , coding
Fault Finding".
sequence:
 Body
 Functions
 Coding Comfort System Central Control Module -J393-
Comfort System Central Control Module J393 , adapting
The following functions can be adapted:
Microsoft
 Individual door opening

 Automatic locking at > 15 km/h
 Automatic unlocking when ignition key is removed
 Unlock return message via access/start authorization
 Unlock return message via radio remote control

 Unlock return message via key switch
 Lock return message via access/start authorization
 Return message for locking via radio remote control
 Return message for locking via key switch

 Return message for ATWS activated
 Country selection for the intelligent alarm horn
 Deactivating comfort operation via radio remote control
 Deactivating ATWS alarm delay when opening driver door
NOTE:  Adaptations listed above are dependent on vehicle equipment level and
market version.
Fault Finding".
sequence:
 Body
 Functions
 Adapting Comfort System Central Control Module -J393-
Comfort System Central Control Module J393 , checking alarm sources of anti-theft warning system
Fault Finding".
Microsoft
sequence:
 Body
 Functions
 Comfort System Central Control Module -J393-, checking alarm sources of anti-theft alarm system
Towing Recognition Control Module J345
NOTE:  The following information applies only to control modules for factory-
installed trailer hitch systems from m.y. 2005. For information on Dealer-
installed trailer hitch system control modules, refer to applicable
installation instructions
Fig. 670: Identifying Comfort System Central Control Module J393 Components
Towing Recognition Control Module J345 - arrow C - is located in luggage compartment, at right on wheel
housing.
NOTE:  Different control modules by the Westfalia and Hella companies are
installed in Touareg.
Microsoft
Towing Recognition Control Module J345 detects from a performance decrease of at least 5 W * See note* See
note the "use of trailer" and sends this information to diverse control modules via CAN-Bus.
Via CAN-Bus, Towing Recognition Control Module J345 is supplied with information (light control) from
Vehicle Electrical System Control Module J519 and Comfort System Central Control Module J393.
Depending on equipment, Towing Recognition Control Module J345 (only control modules from Westfalia)
controls the electric swiveling trailer hitch.
* Control modules from Westfalia: At least the turn signal or parking light must be switched on to detect "use of
trailer".
* Control modules from Hella: At least the turn signal and parking light must be switched on to detect "use of
trailer".
Malfunction detection and malfunction display (control modules from Hella):
Towing Recognition Control Module J345 malfunctions are output via Vehicle Electrical System Control
Module J519.
NOTE:  Output Diagnostic Test Mode (DTM) and coding is not possible for Towing
Recognition Control Module J345 from Hella.
Malfunction detection and malfunction display (control modules from Westfalia):
Towing Recognition Control Module J345 is equipped with On Board Diagnostics (OBD) which assists
troubleshooting.
Towing Recognition Control Module J345 , removing and installing
NOTE:  Removal and installation of Towing Recognition Control Module J345 from
the companies Westfalia and Hella is performed in the same way and is
only described for one control module.
Removing:
Microsoft
Fig. 671: Identifying Comfort System Central Control Module Mounting Bolts
NOTE:  The number of connectors - arrows - at Towing Recognition Control

Module J345 can deviate from the illustration depending on vehicle
equipment and/or manufacturer.
 Disengage connectors - arrows - and disconnect them from Towing Recognition Control Module J345.
 Remove mounting bolt - 1 - and remove Towing Recognition Control Module J345 upward out of
bracket.
Installing:
NOTE:  After installing a new Towing Recognition Control Module J345 (only
modules from Westfalia), it must be coded.
Towing Recognition Control Module J345 (only control modules from the company Westfalia), coding
NOTE:  The following information applies only to coding control modules for
factory-installed trailer hitch systems from m.y. 2005. Guided Fault Finding
supports control module coding for factory-installed trailer hitch systems
only
 To confirm coding on Dealer-installed trailer hitch system control
modules, connect Vehicle Diagnosis, Testing and Information System VAS
5051/5052 and select operating mode Vehicle Self Diagnosis. Select 69
Trailer functions. Select 07 Control Module Coding. Press 2 to confirm
brake light function. For additional information, refer to original
installation instructions
Microsoft
Fault Finding".
sequence:
 Body
 Towing sensor
 Functions
 Coding Control Module for towing sensor
Towing Recognition Control Module J345 (only control modules from the company Westfalia), output Diagnostic Test Mode
(DTM)
NOTE:  Towing Recognition Control Module J345 detects the "use of trailer" only
from a performance decrease of at least 5 W * See note* See note.
 Use the power outlet tester V.A.G 1537/A for the test.
Fig. 672: Power Outlet Tester V.A.G 1537/A

 Power outlet tester V.A.G 1537/A * See note
* Power outlet tester V.A.G 1537/A becomes too warm after a few minutes of use and switches off
automatically. After a cooling off phase, power outlet tester V.A.G 1537/A functions normally again.
Microsoft
Fault Finding".
sequence:
 Body
 Towing sensor
 Functions
 Control Module for towing sensor - output Diagnostic Test Mode (DTM)
Garage Door Opener Control Module J530
Fig. 673: Identifying Garage Door Opener Control Module J530

Garage Door Opener Control Module J530 - arrow - is located in console in molded headliner.
Owners Manual
Garage Door Opener Control Module J530 is not equipped with On Board Diagnostic (OBD).
Garage Door Opener Control Module J530 , removing and installing
Removing:
Microsoft
 Remove console in molded headliner --> 68 - INTERIOR EQUIPMENT .
Fig. 674: Removing/Installing Garage Door Opener Control Module J530

 Remove mounting bolts - arrows - and remove Garage Door Opener Control Module J530 from console.
Installing:
Garage Door Opener Control Module J530 , checking
No further information on testing was available at time of publication.
Heated Windshield Control Module J505
Heated Windshield Control Module J505 - arrow - is located under drivers seat, next to the battery.
Heated Windshield Control Module J505 is activated either by Climatronic Control Module J255 or by A/C
Control Module J301 , depending on vehicle equipment.
Heated Windshield Z2 is switched on by Heated Windshield Control Module J505 under the following
conditions:
 Outside temperature 5°C

Microsoft
 Voltage at Heated Windshield Control Module J505 greater than 12V

 Engine is running
 Button on Climatronic control head is pressed
 No load limitation via Vehicle Electrical System Control Module J519
Depending on the outside temperature the heating period is a maximum of 6 minutes.
Heated front windshield is equipped with On Board Diagnostics (OBD) which assists troubleshooting.
For fault-finding, use the Vehicle Diagnostic, Testing and Information System VAS 5051A , and the "Guided
fault finding" function.
Check heated front windshield.
Heated Windshield Control Module J505 , removing and installing
Removing:
 Swivel drivers seat toward the rear as described in the chapter "disconnecting battery" --> Battery,
disconnecting and reconnecting.

 Remove bolt - 1 - and pull off air vent - 2 - upward.
Microsoft

Fig. 677: Identifying Heated Windshield Control Module Components

 Disengage retaining tab - 3 - and pull Heated Windshield Control Module J505 - 2 - upward out of
bracket, paying attention to lengths of connected wires.
 Disengage and disconnect harness connector - 1 - and remove Heated Windshield Control Module J505 -
2 - from vehicle.
Installing:
Check heated front windshield
Test requirements:
 Outside temperature 5°C

 Voltage at Heated Windshield Control Module J505 greater than 12V
Microsoft
 Engine is running
 Button on Climatronic control head is pressed
 No load limitation via Vehicle Electrical System Control Module J519
NOTE:  Depending on the outside temperature the heating period is a maximum of

6 minutes.
 At this time, it is only possible to test the heated front windshield only
when the test conditions listed above have been met.


 Switch on ignition.
 Turn off all electrical components.
NOTE:  If the indications described in the work procedure do not appear on the
display: User manual for vehicle information, testing and information
system VAS 5051A
 Select operating mode "Guided Fault Finding" on Vehicle Diagnostic, Testing and Information System
VAS 5051A.
sequence:
Microsoft
 Body
 Heating, ventilation, air conditioning --> 87 AIR CONDITIONING
 Climatronic or manual A/C system
 Functions
 Check heated front windshield
WIRING HARNESSES AND CONNECTORS, REPAIRING
Wiring Harnesses and Connectors, Repairing
Microsoft

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2006 Volkswagen Touareg

ELECTRICAL Electrical Equipment

27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Battery systems in the Touareg

Different battery systems are installed on the Touareg:

The one-battery concept:

The one-battery system with auxiliary battery:

NOTE:  The auxiliary battery is installed on vehicles with additional equipment,

The two-battery concept:

NOTE:  Observe --> Self Study Program.

Warnings and Safety Measures

Battery post/terminal, handling instructions

BATTERY, DISCONNECTING AND RECONNECTING

Battery, disconnecting and reconnecting

Battery (vehicles with one-battery concept), disconnecting and connecting

NOTE:  To disconnect battery, anti-theft warning system must be deactivated -->

Fig. 1: Identifying Seat Slide Rail Screws

 Remove screws - arrows -.

Fig. 2: Tilting Seat Frame And Seat To Rear

 Tilt seat frame and seat to rear - arrow -.

Fig. 3: Identifying Bolt & Air Duct

 Remove screw - 1 - and remove air guide - 2 -.

Fig. 4: Identifying Box Clips

 Open battery box clips - arrows - and remove cover.

Fig. 5: Identifying Battery Ground Terminal & Battery Positive Terminal

 Disconnect negative (-) terminal - 1 - from battery.

Special tools, testers and auxiliary items required

Fig. 6: Torque Wrench V.A.G 1331

 Torque wrench V.A.G 1331/

CAUTION: In order to prevent damage to battery housing, battery terminals must be

Battery terminals must not be greased.

Fig. 7: Identifying Battery Ground Line & Battery Positive Terminal

 Refit battery positive (B+) terminal - 2 - on battery positive post.

Fig. 8: Identifying Seat Slide Rail Bolts

Battery disconnecting and reconnecting sequence

CAUTION: Disconnecting and reconnecting batteries on a dual battery system MUST

 Disconnect battery under drivers seat.

Battery (under front left seat), disconnecting

NOTE:  To disconnect battery, anti-theft warning system must be deactivated -->

Fig. 9: Identifying Seat Slide Rail Bolts

 Remove screws - arrows -.

Fig. 10: Tilting Seat Frame And Seat To Rear

 Tilt seat frame and seat to rear - arrow -.

Fig. 11: Identifying Bolt & Air Duct

 Remove screw - 1 - and remove air guide - 2 -.

Fig. 12: Identifying Box Clips

 Open battery box clips - arrows - and remove cover.

 Disconnect negative (-) terminal - 1 - from battery.

Second battery or auxiliary battery, in luggage compartment, disconnecting

Fig. 14: Identifying Auxiliary Battery In Luggage Compartment

 Lift and remove luggage compartment floor cover -arrow-.

Fig. 15: Identifying Retaining Clips & Nuts (Right Side)

Fig. 16: Identifying Retaining Clips & Nuts (Left Side)

Fig. 17: Identifying Retaining Strap Nut

 Remove retaining strap nuts - arrows -.

Fig. 18: Identifying Battery Connection On Positive Terminal

 First, disconnect negative (-) terminal - arrow - from battery.

Fig. 19: Identifying Positive Battery Line

 Then disconnect positive (B+) terminal - arrow - from battery.

Batteries, reconnecting sequence

CAUTION:  Disconnecting and reconnecting batteries on a dual battery system

 Reconnect battery in luggage compartment.

Second battery or auxiliary battery, in luggage compartment, connecting