Volkswagen up! 2012 Workshop Manual
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Volkswagen up! 2012 Workshop Manual

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Service
Workshop Manual
up! 2012 ➤
Electrical system
Edition 03.2017
Service Department. Technical Information

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Summary of Contents for Volkswagen up! 2012

  • Page 1 Service Workshop Manual up! 2012 ➤ Electrical system Edition 03.2017 Service Department. Technical Information...
  • Page 2 In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2017 Volkswagen AG, Wolfsburg D3E80445F60...

  • Page 3: Table Of Contents

    2012 ➤ Electrical system - Edition 03.2017 Contents 27 - Starter, current supply, CCS ........
  • Page 4 2012 ➤ Electrical system - Edition 03.2017 Removing and installing wiper blade ......... .
  • Page 5 2012 ➤ Electrical system - Edition 03.2017 Removing and installing parking aid control unit J446 ......118 Emergency braking function .
  • Page 6 2012 ➤ Electrical system - Edition 03.2017 Contents...

  • Page 7: Starter, Current Supply, Ccs

    2012 ➤ Electrical system - Edition 03.2017 27 – Starter, current supply, CCS Battery (VRL010214; Edition 03.2017) ⇒ “1.1 Assembly overview - battery”, page 1 ⇒ “1.2 Removing and installing battery”, page 3 ⇒ “1.4 Adapting battery monitor control unit J367 ”, page 5 ⇒...
  • Page 8 2012 ➤ Electrical system - Edition 03.2017 1 - Earth wire battery terminal clamp ❑ Comply with the instruc‐ tions regarding threa‐ ded connections of the battery terminals ⇒ page 1 ❑ Depending on vehicle equipment, the battery monitor control unit - J367- may be installed instead.

  • Page 9: Removing And Installing Battery

    2012 ➤ Electrical system - Edition 03.2017 ❑ Nuts for securing battery tray to body: 15 Nm ❑ Bolts for securing bracket of engine control unit to battery tray: 8 Nm Removing and installing battery Special tools and workshop equipment required ♦...

  • Page 10: Removing And Installing Earth Wire With Battery Monitor Control Unit J367

    2012 ➤ Electrical system - Edition 03.2017 – Undo and remove bolt -1- and remove clamping plate -2-. – Remove battery -4-. Installing Caution A loosely fitted battery creates the following dangers: ♦ Shortened service life caused by vibration damage (dan‐...

  • Page 11: Adapting Battery Monitor Control Unit J367

    2012 ➤ Electrical system - Edition 03.2017 Removing – Separate electrical connector -2- on battery monitor control unit - J367- -3-. – Remove battery - A- ⇒ page 3 – Remove engine control unit ⇒ Rep. gr. 23 ; Engine control unit;...
  • Page 12 2012 ➤ Electrical system - Edition 03.2017 battery data are not registered by the sensor while charging. The values concerning the battery state saved in the data bus diag‐ nostic interface do not then correspond to the values of the charged battery.
  • Page 13 2012 ➤ Electrical system - Edition 03.2017 – Then undo the nut of battery terminal clamp for positive cable -1- and pull terminal clamp -2- off battery positive terminal. Connecting battery Caution Comply with instructions regarding threaded connections of the battery terminals ⇒...

  • Page 14: Removing And Installing Battery Tray

    2012 ➤ Electrical system - Edition 03.2017 – Connect battery terminal clamp of earth wire -1- to negative terminal of battery. – Tighten securing nut. – Work through steps listed in table. Procedures after reconnecting battery: Procedure Performed Ignition with ignition key: switch on ignition and then switch off again.

  • Page 15: Checking Battery

    2012 ➤ Electrical system - Edition 03.2017 – Unscrew securing nuts and bolts -2-. – Release the two catches -3-, and pull refrigerant line holder -4- off battery tray. – Unclip all lines from refrigerant line retainer -5-. – Pull catch -6- at bottom of refrigerant line holder -5-, and pull holder upwards off battery tray.

  • Page 16: Alternator

    2012 ➤ Electrical system - Edition 03.2017 Alternator ⇒ “2.1 Assembly overview - alternator”, page 10 ⇒ “2.2 Removing and installing alternator”, page 11 ⇒ “2.3 Checking alternator”, page 14 ⇒ “2.4 Checking poly V-belt”, page 14 ⇒ “2.5 Removing and installing poly V-belt pulley”, page 14 ⇒...

  • Page 17: Removing And Installing Alternator

    2012 ➤ Electrical system - Edition 03.2017 Removing and installing alternator ⇒ “2.2.1 Removing and installing alternator, petrol engine”, page ⇒ “2.2.2 Removing and installing alternator, natural gas engine”, page 12 2.2.1 Removing and installing alternator, pet‐ rol engine Caution To disconnect and reconnect the battery, the procedure de‐...
  • Page 18 2012 ➤ Electrical system - Edition 03.2017 – Release and pull off DF cable connector -4-. – Undo nut -3- and detach B+ wire -2- from connection thread. – Remove alternator - C- -1- by taking it upwards out of vehicle.
  • Page 19 2012 ➤ Electrical system - Edition 03.2017 – Move lock carrier to service position ⇒ General body repairs, exterior; Rep. gr. 50 ; Lock carrier; Moving to and back from service position . – Remove poly V-belt ⇒ Rep. gr. 13 ; Cylinder block, pulley end;...

  • Page 20: Checking Alternator

    2012 ➤ Electrical system - Edition 03.2017 – Drive threaded bushes -A- approx. 4 mm in direction of arrow out of housing of alternator - C- . – Connect battery ⇒ page 5 – Start engine and check belt running.
  • Page 21 2012 ➤ Electrical system - Edition 03.2017 ♦ Socket - VAS 3310- ♦ Torque wrench - V.A.G 1332- Removing – Remove alternator ⇒ page 10 – Clamp alternator in a vice at securing points. – Use socket - VAS 3310- to unscrew poly V-belt pulley securing nut from alternator shaft.
  • Page 22 2012 ➤ Electrical system - Edition 03.2017 ♦ Multipoint adapter - T10474- ♦ Torque wrench - V.A.G 1332- ♦ Socket drive with 8 mm hexagon socket or TORX T50 Removing – Remove alternator ⇒ page 10 – Clamp alternator in a vice at securing points.
  • Page 23 2012 ➤ Electrical system - Edition 03.2017 – Release socket drive -1- and pull off grip -2-. – Turn torque wrench grip -2- 180° and reinsert socket drive. – Set turning direction of torque wrench to anti-clockwise at socket drive.
  • Page 24 2012 ➤ Electrical system - Edition 03.2017 ♦ Torque wrench - V.A.G 1332- ♦ Socket drive with 8 mm hexagon socket or TORX T50 Removing – Remove alternator ⇒ page 10 – Clamp alternator in a vice at securing points.

  • Page 25: Removing And Installing Voltage Regulator

    2012 ➤ Electrical system - Edition 03.2017 – Insert hexagon socket or TORX socket -2- into alternator shaft. – Turn alternator shaft anti-clockwise using torque wrench - V.A.G 1332- -3- in order to tighten poly V-belt pulley with freewheel.
  • Page 26 2012 ➤ Electrical system - Edition 03.2017 – Remove securing bolt and nuts -arrows- and remove deflector cap from alternator. – Unscrew securing bolts of voltage regulator -arrows-. – Remove voltage regulator from alternator. Installing Install in the reverse order of removal observing the following:...
  • Page 27 2012 ➤ Electrical system - Edition 03.2017 ♦ Torque screwdriver - V.A.G 1624- Removing – Remove alternator - C- ⇒ page 11 – Using offset screwdriver for slotted-head screws - VAS 6416- , carefully lever off protective cap -1- at fasteners -arrows-.
  • Page 28 2012 ➤ Electrical system - Edition 03.2017 ♦ Torque wrench - V.A.G 1783/- Removing – Remove alternator ⇒ page 11 – Remove clamping rings -arrows- and remove protective cap from alternator. – Unscrew securing bolts of voltage regulator -arrows-.
  • Page 29 2012 ➤ Electrical system - Edition 03.2017 – Push protective cap into guides -arrows- until it can be heard to engage. Specified torques Component Specified torque Voltage regulator to alternator 2 Nm Protective cap to alternator 4.5 Nm 2. Alternator...

  • Page 30: Starter Motor

    2012 ➤ Electrical system - Edition 03.2017 Starter motor ⇒ “3.1 Assembly overview - starter”, page 24 ⇒ “3.2 Removing and installing starter motor”, page 25 ⇒ “3.3 Checking starter”, page 27 Assembly overview - starter 1 - Starter motor ❑...

  • Page 31: Removing And Installing Starter Motor

    2012 ➤ Electrical system - Edition 03.2017 Removing and installing starter motor ⇒ “3.2.1 Removing and installing starter, manual gearbox”, page ⇒ “3.2.2 Removing and installing starter, automated manual gear‐ box”, page 26 3.2.1 Removing and installing starter, manual...
  • Page 32 2012 ➤ Electrical system - Edition 03.2017 – Unscrew starter securing bolts -2-. – Remove starter -1- by taking it upwards out of the vehicle. Installing Install in the reverse order of removal observing the following: Specified torques ♦...

  • Page 33: Checking Starter

    2012 ➤ Electrical system - Edition 03.2017 – Unscrew starter securing bolts -2-. – Remove starter -1- by taking it upwards out of the vehicle. Installing Install in the reverse order of removal observing the following: Specified torques ♦...

  • Page 34: Cruise Control System (Ccs)

    2012 ➤ Electrical system - Edition 03.2017 Cruise control system (CCS) All the instructions and information for this manual are found in the workshop manual “Electrical System, General Information”. A link to this workshop manual is not possible at present for tech‐...

  • Page 35: Start/Stop System

    2012 ➤ Electrical system - Edition 03.2017 Start/stop system ⇒ “5.1 General description - start/stop system”, page 29 ⇒ “5.2 Removing and installing voltage stabiliser”, page 30 General description - start/stop system General description: The start/stop system is used for reducing fuel consumption by automatically switching off the engine when the vehicle is sta‐...

  • Page 36: Removing And Installing Voltage Stabiliser

    2012 ➤ Electrical system - Edition 03.2017 memory of the diagnostic interface or in the onboard supply con‐ trol unit. If radio, radio/navigation and telephone units have failed together, first check fuse of voltage stabiliser. Removing and installing voltage stabil‐...

  • Page 37: Gauges, Instruments

    2012 ➤ Electrical system - Edition 03.2017 90 – Gauges, instruments Dash panel insert ⇒ “1.1 Assembly overview - dash panel insert”, page 31 ⇒ “1.2 Removing and installing dash panel insert KX2 ”, page 36 Assembly overview - dash panel insert ⇒...
  • Page 38 2012 ➤ Electrical system - Edition 03.2017 1 - Indicator lamp for left turn signal ❑ Switched on 2 - Electronic stabilisation pro‐ gramme (ESP) warning lamp ❑ Flashes: electronic sta‐ bilisation programme (ESP) regulating ❑ Lights up: ESP fault or...
  • Page 39 2012 ➤ Electrical system - Edition 03.2017 tem fault occurred 7 - Main beam warning lamp ❑ Switched on 8 - Rear fog light warning lamp ❑ Switched on 9 - Indicator lamp for electro‐ mechanical power steering (EPS = Electronic Power Steering) ❑...
  • Page 40 2012 ➤ Electrical system - Edition 03.2017 1.1.2 Assembly overview - dash panel insert, indicator lamps, natural gas engine 1 - Indicator lamp for left turn signal ❑ Switched on 2 - Electronic stabilisation pro‐ gramme (ESP) warning lamp ❑...
  • Page 41 2012 ➤ Electrical system - Edition 03.2017 15 - Parking brake indicator lamp ❑ Parking brake applied 16 - Indicator lamp for right turn signal ❑ Switched on 17 - Fuel gauge for petrol 18 - Fuel gauge for natural gas 19 - Indicator lamp for natural gas level ❑...

  • Page 42: Removing And Installing Dash Panel Insert Kx2

    2012 ➤ Electrical system - Edition 03.2017 1.1.3 Assembly overview - dash panel insert, rear Note The dash panel insert must not be dismantled. If necessary, the dash panel insert is renewed as a unit. Warning buzzer Connector Note Pin assignment of connectors on dash panel insert: ⇒...
  • Page 43 2012 ➤ Electrical system - Edition 03.2017 – Undo and remove bolts -arrows- securing dash panel insert -1-. – Push protective films -1- on left and right into gap -arrows- be‐ tween dash panel insert and dash panel cowling. If the pro‐...

  • Page 44: Horn

    2012 ➤ Electrical system - Edition 03.2017 Horn ⇒ “2.1 Assembly overview - horn”, page 38 ⇒ “2.2 Removing and installing treble horn H2 and bass horn H7 ”, page 39 Assembly overview - horn 1 - Bracket ❑ For horn 2 - Bass tone horn - H7- ❑...

  • Page 45: Removing And Installing Treble Horn H2 And Bass Horn H7

    2012 ➤ Electrical system - Edition 03.2017 Removing and installing treble horn - H2- and bass horn - H7- Removing – Unscrew bolt -1-. – Remove bracket together with horns -2-. – Disconnect connector. Removing horns from bracket – Remove horns together with bracket ⇒...

  • Page 46: Windscreen Wash/Wipe System

    2012 ➤ Electrical system - Edition 03.2017 92 – Windscreen wash/wipe system windscreen wiper system. ⇒ “1.1 Assembly overview - windscreen wiper system”, page 40 ⇒ “1.2 Moving wipers to service position”, page 41 ⇒ “1.3 Removing and installing wiper blade”, page 41 ⇒...

  • Page 47: Moving Wipers To Service Position

    2012 ➤ Electrical system - Edition 03.2017 Moving wipers to service position Caution Risk of damaging the bonnet when moving wipers back into the park position. ♦ Do not manoeuvre the vehicle with wiper arms folded out. ♦ The wipers automatically move back to the park position when the wiper switch is operated or when road speed exceeds 6 km/h.

  • Page 48: Removing And Installing Wiper Arms

    2012 ➤ Electrical system - Edition 03.2017 – Press button -1- and pull wiper blade mounting -3- out of wiper arm -2- in -direction of arrow-. Installing Install in the reverse order of removal observing the following: Caution Risk of damage to the vehicle body.
  • Page 49 2012 ➤ Electrical system - Edition 03.2017 Note If it is necessary for the wiper motor to run during the working ♦ procedure, the bonnet must be closed as otherwise the power supply to the wiper motor will be interrupted.

  • Page 50: Adjusting Wiper Arms

    2012 ➤ Electrical system - Edition 03.2017 – Slide legs of puller - T10369/1- -2- under wiper arm -4- as shown in the illustration. Caution The wiper shaft may be damaged. Always use thrust piece -3- to loosen wiper arm.
  • Page 51 2012 ➤ Electrical system - Edition 03.2017 ♦ Torque wrench - V.A.G 1331- Note The removal and installation procedure is described for left-hand drive vehicles. Removal and installation for right-hand drive ve‐ hicles is similar. – Move wipers to park position and then switch off ignition.

  • Page 52: Renewing Windscreen Wiper Rubber

    2012 ➤ Electrical system - Edition 03.2017 Front passenger side: Set wipers to dimension -a- between centre of wiper rubber -1- and upper edge of plenum chamber cover -2-. ♦ Dimension -a- = 30 mm. – Adjust wiper blade park position by moving wiper arm if nec‐...

  • Page 53: Removing And Installing Wiper Motor

    2012 ➤ Electrical system - Edition 03.2017 – Push wiper blade stop -A- back down using a suitable screw‐ driver until wiper rubber blade can no longer be moved in the guide. – Fit new cap -1- and check it is seated securely.
  • Page 54 2012 ➤ Electrical system - Edition 03.2017 ♦ Torque wrench - V.A.G 1331- Removing – All wiper arms to move to park position and then switch off ignition. – Disconnect battery ⇒ page 5 – Remove wiper arms ⇒ page 42 –...

  • Page 55: Renewing Wiper Motor

    2012 ➤ Electrical system - Edition 03.2017 – Screw in securing bolts -arrows-. – Push connector onto connection on wiper motor so that con‐ nector latches into place. – Install plenum chamber cover ⇒ General body repairs, exte‐ rior; Rep. gr. 50 ; Bulkhead; Assembly overview - plenum chamber cover .
  • Page 56 2012 ➤ Electrical system - Edition 03.2017 – Unscrew securing nut -1-, and pull motor crank -3- off wiper motor shaft. – Undo screws -arrows-, then pull retaining plate -4- and wiper motor together with control unit -2- out of the wiper frame.
  • Page 57 2012 ➤ Electrical system - Edition 03.2017 – Press ball head -arrow- of linkage -1- onto motor crank until it latches into place. – Install windscreen wiper motor ⇒ page 47 Specified torques ♦ ⇒ “1.1 Assembly overview - windscreen wiper system”, page 40 1.

  • Page 58: Windscreen Washer System

    2012 ➤ Electrical system - Edition 03.2017 Windscreen washer system ⇒ “2.1 Assembly overview - windscreen washer system”, page 52 ⇒ “2.2 Removing and installing washer fluid reservoir”, page 53 ⇒ “2.3 Removing and installing windscreen washer pump”, page 54 ⇒...

  • Page 59: Removing And Installing Washer Fluid Reservoir

    2012 ➤ Electrical system - Edition 03.2017 lines ⇒ page 63 7 - Connecting pipe with filler neck to reservoir ❑ Removed and installed together with reservoir ⇒ page 53 8 - Washer fluid reservoir ❑ Removing and installing ⇒...

  • Page 60: Removing And Installing Windscreen Washer Pump

    2012 ➤ Electrical system - Edition 03.2017 – Release connecting pipe clip together with filler neck -2- from body. – Undo and remove securing bolt -5- and pull reservoir -4- out of guide -3- in -direction of arrow- towards the rear.

  • Page 61: Removing And Installing Spray Jets

    2012 ➤ Electrical system - Edition 03.2017 – To release, twist securing clips on angled connection pieces -3- and -4-, and pull connection pieces off windscreen and rear window washer pump - V59- -2-. – Collect any escaping washer fluid in a suitable container.

  • Page 62: Adjusting Spray Jets

    2012 ➤ Electrical system - Edition 03.2017 – Depending on the equipment, reconnect plug-in connection -1-. – Fit hose connection -2- onto spray jet and lock hose clip -3-. – Starting at the top, push spray jet into mounting hole until it locks in place audibly.

  • Page 63: Rear Window Wiper System

    2012 ➤ Electrical system - Edition 03.2017 Rear window wiper system ⇒ “3.1 Assembly overview - rear window wiper system”, page 57 ⇒ “3.2 Removing and installing wiper blade”, page 58 ⇒ “3.3 Removing and installing wiper arm”, page 58 ⇒...

  • Page 64: Removing And Installing Wiper Blade

    2012 ➤ Electrical system - Edition 03.2017 Removing and installing wiper blade Removing Caution Risk of damage to the wiper blade. ♦ Joint-free wipers are very flexible. To lift the wiper blades off the rear window, touch them only in the area in which the wiper blades are attached to the wipers.

  • Page 65: Adjusting Wiper Arm

    2012 ➤ Electrical system - Edition 03.2017 – Actuate “rear window wipe” function and allow wiper arm to move to its end position. – Switch off ignition. – Withdraw ignition key. – Fold cover cap -1- of rear window wiper up and unclip it.

  • Page 66: Removing And Installing Rear Window Wiper Motor V12

    2012 ➤ Electrical system - Edition 03.2017 – To set the parking position, align the wiper blade tip with the lowest heating wire of the heated rear window – Adjust rear window wiper park position by moving wiper arm if necessary ⇒...

  • Page 67: Rear Window Washer System

    2012 ➤ Electrical system - Edition 03.2017 Rear window washer system ⇒ “4.1 Assembly overview - rear window washer system”, page 61 ⇒ “4.2 Removing and installing spray jet”, page 61 ⇒ “4.3 Adjusting spray jet”, page 62 Assembly overview - rear window washer system 1 - Filler pipe with filler neck for reservoir for windscreen wash‐...

  • Page 68: Adjusting Spray Jet

    2012 ➤ Electrical system - Edition 03.2017 – Release both catches -arrows- and pull spray jet -1- to rear out of high-level brake light - M25- . Installing – Install in reverse order of removal. – Adjusting spray jet ⇒...

  • Page 69: Washer Fluid Lines

    2012 ➤ Electrical system - Edition 03.2017 Washer fluid lines ⇒ “5.1 Repairing washer fluid lines”, page 63 Repairing washer fluid lines All instructions and notes regarding this chapter are available un‐ der ⇒ Electrical System, General Information; Rep. gr. 92 ; Hose repair .

  • Page 70: Lights, Bulbs, Switches - Exterior

    2012 ➤ Electrical system - Edition 03.2017 94 – Lights, bulbs, switches - exterior Headlights ⇒ “1.1 Assembly overview - headlight”, page 64 ⇒ “1.2 Removing and installing headlight”, page 66 ⇒ “1.3 Adjusting headlights”, page 67 ⇒ “1.4 Adjusting headlight installation position”, page 67 ⇒...
  • Page 71 2012 ➤ Electrical system - Edition 03.2017 1 - Inner bolt securing head‐ light to body ❑ Specified torque: 4 Nm 2 - Bracket securing bolts to body 3 - Carrier 4 - Front left turn signal bulb -...

  • Page 72: Removing And Installing Headlight

    2012 ➤ Electrical system - Edition 03.2017 ❑ Changing headlights over from driving on right to driving on left ⇒ page 73 ❑ Changing headlights over from driving on left to driving on right ⇒ page 74 Removing and installing headlight Special tools and workshop equipment required ♦...

  • Page 73: Adjusting Headlights

    2012 ➤ Electrical system - Edition 03.2017 – Undo and remove inner bolt and upper bolt -arrows- and re‐ move adapter -1- under the upper bolt. – Undo and remove rear bolt -arrow-. – Remove headlight forwards out of body aperture.

  • Page 74: Removing And Installing Front Turn Signal Bulb M5 / M7

    2012 ➤ Electrical system - Edition 03.2017 – Switch off ignition and all electrical consumers, and withdraw ignition key. – Loosen rear securing bolt -arrow-. – Loosen inner and upper securing bolt -arrows-. – Adjust shut lines/flushness to body by pushing in or pulling out alignment bush -arrow- on headlight.
  • Page 75 2012 ➤ Electrical system - Edition 03.2017 Note The removal and installation procedure is described for the left- hand side. The removal and installation procedure for the right- hand side is basically the same. Removing – Switch off ignition and all electrical consumers, and withdraw ignition key.

  • Page 76: Installing Repair Kit For Headlight Housing

    2012 ➤ Electrical system - Edition 03.2017 – Push front turn signal bulb -2- into holder and, at the same time, turn it in -direction of arrow- and pull it out of holder -1-. Front turn signal bulb : 12V, PY21W...
  • Page 77 2012 ➤ Electrical system - Edition 03.2017 – Remove old fastening point -1- as far as necessary until new fastening point is lying evenly on the surface. – Slot new retaining tab -B- onto base of old retaining tab on headlight, ensuring a positive fit, and tighten the two screws -A-.
  • Page 78 2012 ➤ Electrical system - Edition 03.2017 – Remove old retaining tab -1- as far as necessary until repair tab can be attached. – Slot new retaining tab -B- onto base of old retaining tab on headlight, ensuring a positive fit, and tighten the two screws -A-.

  • Page 79: Converting Headlights From Driving On Right To Driving On Left

    2012 ➤ Electrical system - Edition 03.2017 – Remove old retaining tab -1- as far as necessary until repair tab can be attached. – Slot new retaining tab -B- onto base of old retaining tab on headlight, ensuring a positive fit, and tighten the two screws -A-.

  • Page 80: Converting Headlights From Driving On Left To Driving On Right

    2012 ➤ Electrical system - Edition 03.2017 Converting headlights from driving on left to driving on right Note To avoid dazzling oncoming traffic with the asymmetrical ♦ lights, both headlights should normally be converted relevant to the country (driving on the left or right) in which the vehicle is being driven.

  • Page 81: Removing And Installing Dipped Beam Bulb

    2012 ➤ Electrical system - Edition 03.2017 – Swing ball head of actuator -2- towards the right out of mount‐ ing in headlight -1- and remove actuator -3- from headlight housing. Installing Install in the reverse order of removal, observing the following: Caution Risk of damage to the headlight.
  • Page 82 2012 ➤ Electrical system - Edition 03.2017 Note The illustrations show removal and installation of the bulb for ♦ dipped beam and main beam of left headlight. Removal and installation of the bulb for dipped beam and main beam of right headlight are analogous.

  • Page 83: Removing And Installing Bulb For Daytime Running Light/Side Light

    2012 ➤ Electrical system - Edition 03.2017 1.11 Removing and installing bulb for day‐ time running light/side light Caution Filament bulbs and gas discharge bulbs under pressure! Danger of injury due to bursting filament lamps and gas dis‐ charge bulbs! ♦...
  • Page 84 2012 ➤ Electrical system - Edition 03.2017 – Pull bulb for side light/daytime running light -2- in a straight line out bulb holder -1-. Bulb for side light/daytime running light: 12V, 21/5W Installing Install in the reverse order of removal, observing the following: Caution Risk of damage to the headlight.

  • Page 85: Fog Lights

    2012 ➤ Electrical system - Edition 03.2017 Fog lights ⇒ “2.1 Assembly overview - fog lights”, page 79 ⇒ “2.2 Removing and installing fog light”, page 79 ⇒ “2.3 Removing and installing fog light bulb”, page 80 ⇒ “2.4 Adjusting fog lights”, page 81...

  • Page 86: Removing And Installing Fog Light Bulb

    2012 ➤ Electrical system - Edition 03.2017 Removing – Switch off ignition and all electrical consumers, and withdraw ignition key. – Detach front area of liner in front wheel housing to gain access to back of fog light ⇒ General body repairs, exterior; Rep. gr.

  • Page 87: Adjusting Fog Lights

    2012 ➤ Electrical system - Edition 03.2017 – Release and pull off connector -1-. – Turn bulb holder -2- together with fog light bulb in -direction of arrow- and remove from fog light housing -3-. Note The fog light bulb is permanently attached to the bulb holder and cannot be renewed separately.

  • Page 88: Turn Signal Repeater

    2012 ➤ Electrical system - Edition 03.2017 Turn signal repeater ⇒ “3.1 Removing and installing turn signal repeater”, page 82 ⇒ “3.2 Removing and installing turn signal light bulb”, page 83 Removing and installing turn signal re‐ peater The turn signal lights are built into the front wings on the left and right.

  • Page 89: Removing And Installing Turn Signal Light Bulb

    2012 ➤ Electrical system - Edition 03.2017 – Fit holder together with glass base bulb -1- onto bulb housing -2- so that retaining lugs -arrows- are opposite one another. – Insert bulb housing into body, starting with the spring clip -2-, press in direction of spring clip -arrow- and secure it in body with fixed anchor point -1-.

  • Page 90: Tail Lights

    2012 ➤ Electrical system - Edition 03.2017 Tail lights ⇒ “4.1 Assembly overview - tail lights in body”, page 84 ⇒ “4.2 Removing and installing bulb carrier”, page 85 ⇒ “4.3 Removing and installing tail light bulb M2 / M4 ”, page 85 ⇒...

  • Page 91: Removing And Installing Bulb Carrier

    2012 ➤ Electrical system - Edition 03.2017 Removing and installing bulb carrier Note The removal and installation procedure is described for the left- hand side. The removal and installation procedure for the right- hand side is basically the same.

  • Page 92: Removing And Installing Tail Light

    2012 ➤ Electrical system - Edition 03.2017 Removing and installing tail light Note The removal and installation procedure is described for the left- hand side. The removal and installation procedure for the right- hand side is basically the same.

  • Page 93: Removing And Installing Rear Fog Light Bulb L46 / L47

    2012 ➤ Electrical system - Edition 03.2017 – Release and pull off connector -arrow- and then remove tail light. Installing Install in the reverse order of removal, observing the following: Caution Risk of wiring damage. The wiring harness for the tail lights could become trapped when installing.

  • Page 94: Removing And Installing Brake And Tail Light Bulb M21 / M22

    2012 ➤ Electrical system - Edition 03.2017 Removing and installing brake and tail light bulb -M21- / -M22- Note The removal and installation procedure is described for the left- hand side. The removal and installation procedure for the right- hand side is basically the same.

  • Page 95: Removing And Installing Turn Signal Bulb

    2012 ➤ Electrical system - Edition 03.2017 Removing and installing turn signal bulb Note The removal and installation procedure is described for the left- hand side. The removal and installation procedure for the right- hand side is basically the same.

  • Page 96: High-Level Brake Light

    2012 ➤ Electrical system - Edition 03.2017 High-level brake light ⇒ “5.1 Removing and installing additional brake light”, page 90 Removing and installing additional brake light Caution When removing and installing components that are in view (switches, covers, trim and so on), mask off areas in which...
  • Page 97 2012 ➤ Electrical system - Edition 03.2017 – Insert assembly wedge - T10039/1- -1- at top between bulb for high-level brake light - M25- -2- and rear lid. – Release catch of bulb for high-level brake light - M25- by pushing assembly wedge in direction of front of vehicle.
  • Page 98 2012 ➤ Electrical system - Edition 03.2017 – Pull out hose lock -arrow- and pull off hose connection -1- from high-level brake light bulb - M25- . – Release and pull connector -2- off and remove high-level brake light bulb - M25- .

  • Page 99: Number Plate Light

    2012 ➤ Electrical system - Edition 03.2017 Number plate light ⇒ “6.1 Removing and installing number plate light X4 / X5 ”, page ⇒ “6.2 Removing and installing bulb for number plate light X4 / X5 ”, page 93...
  • Page 100 2012 ➤ Electrical system - Edition 03.2017 – Pull glass base bulb -2- in -direction of arrow- out of bulb holder -1- in a straight line. Bulb for number plate light - X- : glass-base bulb 12 V, 5 W.

  • Page 101: Steering Column Switch Module

    2012 ➤ Electrical system - Edition 03.2017 Steering column switch module Steering column switch module ► 10.2013 ⇒ “7.1.1 Removing and installing steering column switch module ”, page 95 ⇒ “7.1.2 Removing and installing airbag coil connector and return ring with slip ring F138 ”, page 97...
  • Page 102 2012 ➤ Electrical system - Edition 03.2017 ♦ Headlight dipper and flasher switch - E4- ♦ Parking light switch - E19- ♦ Intermittent wiper switch - E22- ♦ Rear window wiper switch - E34- ♦ Intermittent wiper regulator - E38- ♦...
  • Page 103 2012 ➤ Electrical system - Edition 03.2017 – Move the steering column to its lowest position by means of the steering column adjustment feature and lock it in place with the locking lever. – Remove steering column trim ⇒ General body repairs, interior;...
  • Page 104 2012 ➤ Electrical system - Edition 03.2017 7.1.3 Removing and installing steering angle sender - G85- Note The steering angle sender is fitted depending on the equipment scope. The steering angle sender - G85- is integrated in the coil connec‐...
  • Page 105 2012 ➤ Electrical system - Edition 03.2017 – Select operating mode “Guided Fault Finding” in vehicle diag‐ nosis tester . – Using “GoTo” button, select “Functions/component” and then the following menu options in succession: ♦ Body ♦ Electrical system ♦...
  • Page 106 2012 ➤ Electrical system - Edition 03.2017 Note For reasons of clarity, the lock cylinder is shown in the following illustration without ignition key. – Insert a piece of steel wire (approx. diameter: 1.2 mm) into hole -arrow- next to ignition key.
  • Page 107 2012 ➤ Electrical system - Edition 03.2017 Caution ♦ The steering lock could be destroyed. ♦ If the steering lock is actuated without lock cylinder, it will block and must be renewed. ♦ The steering lock must not be actuated without lock cylin‐...
  • Page 108 2012 ➤ Electrical system - Edition 03.2017 WARNING Danger of eye injury from drilling swarf. When drilling out, swarf may fly off and cause eye injury. Wear safety goggles. – Undo screw -1- and remove cable. – Drill out shear-head bolts -arrows- of steering lock housing -2-.

  • Page 109: Steering Column Switch Module 11.2013

    2012 ➤ Electrical system - Edition 03.2017 Steering column switch module 11.2013 ► ⇒ “7.2.1 Assembly overview - steering column switch module”, page 103 ⇒ “7.2.2 Removing and installing airbag coil connector and return ring with slip ring F138 ”, page 104 ⇒...

  • Page 110: Removing And Installing Airbag Coil Connector And Return Ring With Slip Ring F138

    2012 ➤ Electrical system - Edition 03.2017 1 - Shear bolt ❑ For steering lock hous‐ ❑ Qty. 2 2 - Ignition key withdrawal lock solenoid - N376- ❑ Only on vehicles with automatic gearbox or dual clutch gearbox ❑...
  • Page 111 2012 ➤ Electrical system - Edition 03.2017 ♦ Torque screwdriver - V.A.G 1624- Depending on vehicle equipment, the steering angle sender - F138- may be integrated in the airbag coil connector and return ring with slip ring - G85- .

  • Page 112: Removing And Installing Steering Column Combination Switch E595

    2012 ➤ Electrical system - Edition 03.2017 – Disconnect connector -2- on airbag coil connector and return ring with slip ring - F138- -1-. – Unscrew bolts -arrows- of airbag coil connector and return ring with slip ring - F138- -1-.
  • Page 113 2012 ➤ Electrical system - Edition 03.2017 Removing – Remove airbag coil connector and return ring with slip ring - F138- ⇒ page 104 – Disconnect left connector -2- from steering column combina‐ tion switch - E595- -1-. – Disconnect right connector -2- from steering column combi‐...

  • Page 114: Removing And Installing Turn Signal Switch E2

    2012 ➤ Electrical system - Edition 03.2017 7.2.4 Removing and installing turn signal switch - E2- Depending on vehicle equipment, the following components are integrated into the steering column combination switch - E595- as one unit: ♦ Turn signal switch - E2- ♦...

  • Page 115: Removing And Installing Intermittent Wiper Switch E22

    2012 ➤ Electrical system - Edition 03.2017 7.2.6 Removing and installing intermittent wiper switch - E22- Depending on vehicle equipment, the following components are integrated into the steering column combination switch - E595- as one unit: ♦ Turn signal switch - E2- ♦...

  • Page 116: Removing And Installing Lock Cylinder

    2012 ➤ Electrical system - Edition 03.2017 7.2.7 Removing and installing ignition/starter switch - D- Removing – Disconnect battery ⇒ page 5 – Remove lower steering column trim ⇒ Rep. gr. 68 ; General body repairs, interior; Compartments/covers; Removing and installing lower steering column trim .
  • Page 117 2012 ➤ Electrical system - Edition 03.2017 ♦ Locking pin - T40011- or suitable welding wire Note The immobiliser reader coil - D2- is integrated into the lock ♦ cylinder and cannot be renewed individually. If it is defective, the complete lock cylinder must be renewed.

  • Page 118: Removing And Installing Steering Lock Housing

    2012 ➤ Electrical system - Edition 03.2017 – Fold aside ignition key as far as possible. – Insert locking pin - T40011- or suitable welding wire as far as stop in hole -2-, and release lock cylinder -1-. – Pull lock cylinder -1- together with immobiliser reader coil - D2- out of steering lock housing.
  • Page 119 2012 ➤ Electrical system - Edition 03.2017 WARNING Risk of damage to the electronic components due to electro‐ static discharge. ♦ Before disconnecting the electrical connector, the me‐ chanic must electrostatically discharge himself or herself by briefly grasping hold of door striker plate or similar.

  • Page 120: Removing And Installing Ignition Key Withdrawal Lock Solenoid N376

    2012 ➤ Electrical system - Edition 03.2017 – Drill out shear heads -arrows- using an angle drill and an 8.5 mm drill bit. – Remove steering lock housing from steering column. The following components must be removed to renew the steering lock housing: ♦...

  • Page 121: Parking Aid

    2012 ➤ Electrical system - Edition 03.2017 Parking aid ⇒ “8.1 Assembly overview – parking aid”, page 115 ⇒ “8.2 Removing and installing rear parking aid warning buzzer H15 ”, page 115 ⇒ “8.3 Adapting volume and frequency of rear parking aid warning buzzer”, page 116...

  • Page 122: Adapting Volume And Frequency Of Rear Parking Aid Warning Buzzer

    2012 ➤ Electrical system - Edition 03.2017 Removing – Switch off ignition and all electrical consumers, and withdraw ignition key. – Remove left luggage compartment side trim ⇒ General body repairs, interior; Rep. gr. 70 ; Luggage compartment trim; As‐...
  • Page 123 2012 ➤ Electrical system - Edition 03.2017 Note 3 parking aid senders are built into the rear bumper cover: ♦ To remove and install the two outer parking aid senders, the ♦ bumper cover must not be removed. The senders can be reached through the wheel housing.

  • Page 124: Removing And Installing Parking Aid Control Unit J446

    2012 ➤ Electrical system - Edition 03.2017 – Release connector -2- and then pull it off sender -1-. Installing Install in the reverse order of removal observing the following: Caution Function problems could occur if an incorrect or damaged iso‐...
  • Page 125 2012 ➤ Electrical system - Edition 03.2017 – Release and pull off connector -2-. – Undo the two nuts -arrows- and remove parking aid control unit - J446- -1-. Installing Install in the reverse order of removal observing the following: –...

  • Page 126: Emergency Braking Function

    2012 ➤ Electrical system - Edition 03.2017 Emergency braking function ⇒ “9.1 Removing and installing City Emergency Braking System”, page 120 Removing and installing City Emergen‐ cy Braking System General description ⇒ page 120 Removing ⇒ page 121 Installing ⇒...
  • Page 127 2012 ➤ Electrical system - Edition 03.2017 Removing – Switch off ignition and all electrical consumers, and withdraw ignition key. – Remove cover from interior mirror ⇒ General body repairs, interior; Rep. gr. 68 ; Interior mirror; Assembly overview - in‐...

  • Page 128: Lights, Bulbs, Switches - Interior

    2012 ➤ Electrical system - Edition 03.2017 96 – Lights, bulbs, switches - interior Lights ⇒ “1.1 Removing and installing front passenger airbag warning lamp”, page 122 ⇒ “1.2 Removing and installing indicator lamp for central locking SAFELOCK function”, page 122 ⇒...

  • Page 129: Removing And Installing Front Interior And Reading Light

    2012 ➤ Electrical system - Edition 03.2017 Removing and installing front interior and reading light ⇒ “1.4.1 Removing and installing front interior light and reading light in vehicles without panoramic sunroof”, page 123 ⇒ “1.4.2 Removing and installing front interior and reading light in vehicles with panoramic sunroof”, page 125...
  • Page 130 2012 ➤ Electrical system - Edition 03.2017 – Using the removal wedge - VAS 3409- or a suitable screw‐ driver, carefully lever out the lens -1- at its catches -arrows- and remove it from the front interior light - W1- -2-.
  • Page 131 2012 ➤ Electrical system - Edition 03.2017 1.4.2 Removing and installing front interior and reading light in vehicles with panor‐ amic sunroof The front interior and reading light contains the following compo‐ nents: ♦ Front interior light - W1- ♦...

  • Page 132: Removing And Installing Bulbs For Front Interior And Reading Light

    2012 ➤ Electrical system - Edition 03.2017 – Release the locking lugs by pushing them in -direction of arrows- and remove front interior and reading light -1- from roof trim, taking connected wiring lengths into con‐ sideration. – Release and detach connectors -1- and -2- and then remove front interior and reading light.
  • Page 133 2012 ➤ Electrical system - Edition 03.2017 – Remove bulb -2- from holder -1-. Bulb for front interior light - W1- : festoon bulb 12V, 10W Installing Installation is carried out in reverse order of removal. 1.5.2 Removing and installing bulbs for front...

  • Page 134: Removing And Installing Front Reading Lights

    2012 ➤ Electrical system - Edition 03.2017 – Turn bulb holder -2- together with bulb of front interior light - W1- in -direction of arrow- and then remove. – Pull bulb -1- in -direction of arrow- out of bulb holder -2-.
  • Page 135 2012 ➤ Electrical system - Edition 03.2017 – Turn bulb holder -1- together with bulb of reading light in -direction of arrow- and then remove. – Pull bulb -1- in -direction of arrow- out of bulb holder -2-. Renewing bulb for front passenger reading light - W13- or driver...

  • Page 136: Controls

    2012 ➤ Electrical system - Edition 03.2017 Controls ⇒ “2.1 Removing and installing light switch”, page 130 ⇒ “2.2 Removing and installing headlight range control regulator”, page 131 ⇒ “2.3 Removing and installing switch module in middle of dash panel”, page 131...

  • Page 137: Removing And Installing Headlight Range Control Regulator

    2012 ➤ Electrical system - Edition 03.2017 – Attach connector so that it latches into place. – Hold light switch and press rotary knob of light switch - E1- firmly into dash panel -1- and then turn knob clockwise a little -2-.

  • Page 138: Removing And Installing Start-Stop Operation Button

    2012 ➤ Electrical system - Edition 03.2017 Special tools and workshop equipment required ♦ Removal wedge - VAS 3409- Note When removing and installing components that are in view ♦ (switches, covers, trim and so on), mask off areas in which...

  • Page 139: Removing And Installing Hazard Warning Light Switch

    2012 ➤ Electrical system - Edition 03.2017 Removing and installing hazard warning light switch The hazard warning light switch - E229- is an integral part of the switch module in middle of dash panel and cannot be replaced separately.

  • Page 140: Removing And Installing Operating Unit For Window Regulator In Driver Door E512

    2012 ➤ Electrical system - Edition 03.2017 ♦ Removal wedge - VAS 3409- Removing – Switch off ignition and all electrical consumers, and withdraw ignition key. – Remove cover on side of dash panel on front passenger side ⇒ General body repairs, interior; Rep. gr. 68 ; Storage com‐...

  • Page 141: Removing And Installing Front Window Regulator Switch

    2012 ➤ Electrical system - Edition 03.2017 ♦ Mirror adjustment switch - E43- Front passenger side: ♦ Front right window regulator switch - E41- Note The operating unit for window regulator in driver door - E308- ♦ must be removed before the driver side interior locking button for central locking system - E43- and the mirror adjustment switch - E512- can be removed or installed.

  • Page 142: Removing And Installing Mirror Adjustment Switch E43 / E168

    2012 ➤ Electrical system - Edition 03.2017 ♦ Removal wedge - VAS 3409- Note The following illustrations show removal and installation of the ♦ front left window regulator switch - E40- . Removal and installation of the front right window regulator ♦...

  • Page 143: Removing And Installing Driver Side Interior Locking Button For Central Locking System

    2012 ➤ Electrical system - Edition 03.2017 ♦ Removal wedge - VAS 3409- Removing – Remove switch element on driver side ⇒ page 134 – Release the two catches -arrows-, and push mirror adjustment switch - E43- -1- out of operating unit for window regulator in driver door - E512- .

  • Page 144: Removing And Installing Centre Console Switch Module

    2012 ➤ Electrical system - Edition 03.2017 – Release the two catches -arrows-, and push driver side interior locking button for central locking system - E308- -1- out of op‐ erating unit for window regulator in driver door - E512- .

  • Page 145: Removing And Installing Pushbutton For Emergency Braking Function

    2012 ➤ Electrical system - Edition 03.2017 – First insert right side of mounting frame -1- into cover of centre console -2- and then push mounting frame in on left side to ensure it locks into place securely. 2.14...

  • Page 146: Immobiliser

    ♦ The respective vehicle identification number must be specified when re-ordering ignition keys. ♦ It is no longer possible to adapt components of other brands for use in Volkswagen vehicles. Immobiliser components: ♦ Immobiliser control unit - J362- ⇒ page 140 ♦...

  • Page 147: Removing And Installing Immobiliser Reader Coil

    2012 ➤ Electrical system - Edition 03.2017 Removing and installing immobiliser reader coil The immobiliser reader coil - D2- is joined to the ignition switch lock cylinder and cannot be renewed individually. – Removing and installing lock cylinder ⇒ page 99...

  • Page 148: Cigarette Lighter, Socket

    2012 ➤ Electrical system - Edition 03.2017 Cigarette lighter, socket ⇒ “4.1 Removing and installing cigarette lighter”, page 142 ⇒ “4.2 Removing and installing 12 V socket”, page 142 ⇒ “4.3 Removing and installing bulb for illuminating cigarette light‐...

  • Page 149: Wiring

    2012 ➤ Electrical system - Edition 03.2017 97 – Wiring Relay carriers, fuse holders, elec‐ tronics boxes ⇒ “1.1 Removing and installing electronics box (E-box)”, page 143 ⇒ “1.2 Removing and installing relay and fuse holder in electronics box”, page 145 ⇒...
  • Page 150 2012 ➤ Electrical system - Edition 03.2017 – Undo and remove all nuts of the wiring connections -arrows A- and remove wires from the connecting threads. – Unscrew nut -arrow B-. – Release the catches -arrow C- on each side of the electronics box holder and remove electronics Box together with holder upwards off the battery.

  • Page 151: Removing And Installing Relay And Fuse Holder In Electronics Box

    2012 ➤ Electrical system - Edition 03.2017 Removing and installing relay and fuse holder in electronics box The fuse holder in the electronics box is attach to the side of the electronics box on the battery. Special tools and workshop equipment required ♦...
  • Page 152 2012 ➤ Electrical system - Edition 03.2017 – Undo and remove the 2 nuts -arrows- and remove electrocon‐ ductive plate -1- and multiple fuse -2- from electronics box. – Turn electronics box over, release locking lug -arrow- and pull fuse holder -1- upwards off the electronics box.

  • Page 153: Removing And Installing Relay And Fuse Holder Behind Dash Panel On Driver Side

    2012 ➤ Electrical system - Edition 03.2017 – Insert a new multiple fuse -2-, and screw on nuts -arrows-. – Connect battery ⇒ page 5 Specified torques Component Specified torque Nuts -arrows- 6 Nm Removing and installing relay and fuse holder behind dash panel on driver side ⇒...
  • Page 154 2012 ➤ Electrical system - Edition 03.2017 Note The illustrations show removal and installation of the fuse ♦ holder in an LHD vehicle. Removal and installation of the fuse holder in an RHD vehicle ♦ are analogous. Removing – Switch off ignition and all electrical consumers, and withdraw ignition key.
  • Page 155 2012 ➤ Electrical system - Edition 03.2017 ♦ Torque wrench - V.A.G 1410- ♦ Release tool set - VAS 1978/35- Caution To disconnect and reconnect the battery, the procedure de‐ scribed in the workshop manual should be strictly adhered to ⇒...
  • Page 156 2012 ➤ Electrical system - Edition 03.2017 – Undo screws -arrows- and pull fuse carrier -1- out of relay car‐ rier, taking connected wiring lengths into consideration. – Make a note of the fuse assignment and remove all fuses from the fuse carrier.
  • Page 157 2012 ➤ Electrical system - Edition 03.2017 ♦ Release tool set - VAS 1978/35- Caution To disconnect and reconnect the battery, the procedure de‐ scribed in the workshop manual should be strictly adhered to ⇒ page 5 Note The illustrations show removal and installation of the relay ♦...
  • Page 158 2012 ➤ Electrical system - Edition 03.2017 – Remove the 3 nuts (width across flats 10 mm) -arrows- and pull relay carrier -1- off threaded pins, taking connected wiring lengths into consideration. – Cut the cable tie -arrow- and unclip cable fuse -1- from relay carrier.

  • Page 159: Select Control Units

    2012 ➤ Electrical system - Edition 03.2017 Select Control units ⇒ “2.1 Removing and installing onboard supply control unit J519 ”, page 153 ⇒ “2.2 Removing and installing data bus diagnostic interface J533 ”, page 155 Removing and installing onboard supply...
  • Page 160 2012 ➤ Electrical system - Edition 03.2017 Note If the onboard supply control unit - J519- is to be renewed, the ♦ procedure for “replacing onboard supply control unit” ⇒ page 155 must always be carried out for reading the codes stored in the control unit.

  • Page 161: Removing And Installing Data Bus Diagnostic Interface J533

    2012 ➤ Electrical system - Edition 03.2017 – Pull the two clips -1- of the primary locking system downwards in -direction of arrow- and pull the two connectors -A- and -B- off the onboard supply control unit - J519- -2-.

  • Page 162: Connectors

    2012 ➤ Electrical system - Edition 03.2017 Connectors ⇒ “3.1 Repairing electrical wiring harnesses and plug-in connec‐ tions”, page 156 Repairing electrical wiring harnesses and plug-in connections All instructions and notes regarding this chapter are available un‐ der ⇒ Electrical System, General Information; Rep. gr. 97 ;...

  • Page 163: Vehicle Diagnosis, Testing And Information Systems

    The following processes are performed with this test program: ♦ System test for online connection ♦ Check of user authorization ♦ Test for correct line connection to Volkswagen database Prerequisite: tester must have an online connection (network connection): – Online system test ⇒ Vehicle diagnostic tester.

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