Electrical system

Chapter overview

• Starter, current supply, CCS
  1
• 1 Battery
  1
• 1.1 Fundamentals for batteries
  1
• 1.2 Types of battery
  1
• 1.3 Warning notices and safety regulations
  1
• 1.4 Battery load test
  1
• 2 Checking battery
  2
• 3 Charging battery
  3
• 4 Disconnecting and connecting battery
  4
• 4.1 Disconnect battery
  4
• 4.2 Connecting battery
  5
• 5 Removing and installing battery
  7
• 5.1 Vehicles with bolted-on fuse holder
  7
• 5.2 Vehicles with clipped-on fuse holder
  10
• 6 Specified torques: battery
  14
• 7 Starter motor
  15
• 7.1 Checking starter B
  15
• 7.2 Removing and installing starter
  15
• 8 Specified torques: starter
  21
• 9 Alternator
  22
• 9.1 Checking alternator C
  22
• 9.2 Alternator ► 04.99
  22
• 9.3 Alternator 05.99 ►
  24
• 9.4 Alternator 05.00 ► (Hitachi)
  26
• 9.5 Checking poly V-belt
  27
• 9.6 Alternator, 4-cyl. 16V 1.4 l and 1.6 l injection engine
  28
• 9.7 Alternator, 4-cyl. 1.6 l, 1.8 l and 2.0 l injection engine
  33
• 9.8 Alternator, 5-cyl. 2.3 l injection engine
  40
• 9.9 Alternator, 6-cyl. injection engine
  46
• 9.10 Alternator, 4-cyl. SDI/TDI engine
  51
• 9.11 Alternator, 4-cyl. unit-injector diesel engine
  59
• 9.12 Renewing poly V-belt pulley on alternator
  63
• 9.13 Installing poly V-belt pulley with freewheel
  65
• 10 Specified torques: alternator
  67
• 10.1 General torque settings for all vehicles
  67
• 10.2 Specified torques for vehicles with 4-cyl. 1.4 l and 1.6 l 16V injection engine
  67
• 10.3 Specified torques for vehicles with 4-cyl. 1.6 l, 1.8 l and 2.0 l injection engine
  67
• 10.4 Specified torques for vehicles with 5-cyl. 2.3 l injection engine
  67
• 10.5 Specified torques for vehicles with 6-cyl. injection engine
  67
• 10.6 Specified torques for vehicles with 4-cyl. SDI/TDI engine
  67
• 10.7 Specified torques for vehicles with 4-cyl. unit-injector diesel engine
  68
• 11 Cruise control system (CCS)
  69
• Gauges, instruments
  70
• 1 Dash panel insert
  70
• 1.1 General description
  70
• 1.2 Renewing dash panel insert
  71
• 1.3 Removing and installing dash panel insert
  71
• 1.4 Dash panel insert, rear view
  73
• 1.5 Pin assignment of connections on dash panel insert ► 04.99
  75
• 1.6 Pin assignment of connections on dash panel insert 05.99 ►
  78
• 1.7 Pin assignment of connections on dash panel insert 05.02 ►
  81
• 1.8 Warning lamp symbols in dash panel insert
  83
• 2 Service interval display
  84
• 2.1 Resetting service interval display
  84
• Windscreen wash/wipe system
  85
• 1 Windscreen wiper system
  85
• 1.1 Removing and installing windscreen wiper system
  85
• 1.2 Removing and installing wiper arms
  89
• 1.3 Adjusting wiper blade park position
  89
• 1.4 Removing and installing wiper rubber
  90
• 1.5 Removing and installing aerodynamic wipers
  91
• 1.6 Removing and installing wiper rubber on aero wiper
  92
• 1.7 Removing and installing rain sensor G213
  93
• 1.8 Fitting a new adhesive pad to the rain sensor (Valeo)
  95
• 2 Windscreen washer system
  100
• 2.1 Assembly overview - windscreen washer system, Golf/Bora
  100
• 2.2 Removing and installing washer fluid reservoir
  102
• 2.3 Removing and installing windscreen and rear window washer pump V59
  104
• 2.4 Removing and installing windscreen washer fluid level sender G33
  104
• 2.5 Removing and installing windscreen washer system spray jets
  105
• 2.6 Adjusting spray jets for windscreen washer system
  106
• 3 Rear window wiper system
  107
• 3.1 Assembly overview - rear window wiper system
  107
• 3.2 Removing and installing rear window wiper
  108
• 3.3 Adjusting rear window wiper park position
  110
• 3.4 Renewing wiper rubber blade
  111
• 4 Rear window washer system
  112
• 4.1 Assembly overview - windscreen washer system, Golf Saloon
  112
• 4.2 Assembly overview - windscreen washer system, Golf/Bora Estate
  112
• 4.3 Renewing spray jet
  114
• 4.4 Adjusting spray jet
  114
• 5 Headlight washer system
  115
• 5.1 Assembly overview - headlight washer system, Golf/Bora
  115
• 5.2 Removing and installing headlight washer system pump V11
  117
• 5.3 Removing and installing spray jet pop-up cylinders
  117
• 5.4 Removing and installing spray jet retainer
  118
• 5.5 Adjusting headlight washer system spray jets
  119
• 5.6 Bleeding headlight washer system
  119
• 6 Washer fluid line hose couplings
  120
• 7 Hose repair
  121
• 8 Specified torques: window wash/wipe system
  122
• Lights, bulbs, switches - exterior
  123
• 1 Main headlights, Golf
  123
• 1.1 Assembly overview - headlight
  123
• 1.2 Removing and installing headlight
  125
• 1.3 Renewing headlight bulbs
  125
• 1.4 Repairing upper headlight securing tabs
  130
• 1.6 Headlight conversion for driving on left/right
  132
• 1.7 Converting headlights designed for driving on the left to driving on the right
  134
• 1.8 Adjusting headlights
  135
• 2 Main headlights - Bora
  136
• 2.1 Assembly overview - headlight
  136
• 2.2 Removing and installing headlight
  137
• 2.3 Renewing headlight bulbs
  138
• 2.4 Repairing upper headlight securing tabs
  142
• 2.6 Converting headlights designed for driving on the right to driving on the left
  144
• 2.7 Converting headlights designed for driving on the left to driving on the right
  145
• 2.8 Adjusting headlights
  146
• 3 Headlight with gas discharge light
  147
• 3.1 Fault finding
  147
• 3.2 Assembly overview - headlights with gas discharge bulbs, Golf/Bora ► 04.02
  147
• 3.3 Operation and safety notes for gas discharge lamps
  149
• 3.4 Renewing bulbs in gas discharge headlight, Golf/Bora ► 04.02
  151
• 3.6 Removing and installing headlight range control unit J431, vehicles ► 04.02
  157
• 3.7 Assembly overview - headlights with gas discharge bulbs, Golf 05.02 ►
  158
• 3.8 Assembly overview - headlights with gas discharge bulbs, Bora 05.02 ►
  160
• 3.9 Renewing bulbs in gas discharge headlight, Golf/Bora 05.02 ►
  162
• 3.10 Removing and installing headlight range control unit, Golf 05.02 ►
  169
• 3.11 Removing and installing headlight range control unit, Bora 05.02 ►
  170
• 3.12 Removing and installing gas discharge light starter unit N195, Golf
  171
• 3.13 Removing and installing gas discharge light starter unit N195, Bora
  171
• 3.16 Removing and installing headlight
  172
• 3.17 Repairing upper headlight securing tabs
  172
• 3.18 Adjusting headlights with gas discharge bulbs
  172
• 3.19 Headlight conversion for left-hand/right-hand traffic
  172
• 3.24 Coding headlight range control unit J431
  177
• 4 Turn signal repeaters
  179
• 4.1 Removing and installing turn signal repeaters
  179
• 5 Tail light clusters
  180
• 5.1 Assembly overview - tail light cluster, Golf
  180
• 5.2 Assembly overview - tail light cluster, Bora
  180
• 5.3 Assembly overview - tail light cluster, Golf Estate/Bora Estate
  181
• 5.4 Removing and installing tail light cluster, Golf
  182
• 5.5 Removing and installing tail light cluster, Bora
  183
• 5.6 Removing and installing tail light cluster, Golf Estate/Bora Estate
  183
• 5.7 Removing and installing tail light cluster bulb carrier, Golf/Bora
  184
• 5.8 Removing and installing tail light cluster bulb carrier, Golf Estate/Bora Estate
  185
• 5.9 Specified torques: tail light cluster
  185
• 6 Number plate light
  186
• 6.1 Number plate light X, Golf
  186
• 6.2 Number plate light X, Golf Estate/ Bora Estate
  188
• 6.3 Number plate light X, Bora
  188
• 7 Additional brake lights
  189
• 7.1 Removing and installing high-level brake light, Golf
  189
• 7.2 Removing and installing high-level brake light, Bora
  190
• 7.3 Removing and installing high-level brake light, Golf Estate/Bora Estate
  191
• 8 Steering column switch
  193
• 8.1 Removing and installing steering column switch
  193
• 8.2 Removing and installing horn plate H
  194
• 8.3 Pin assignment on steering column switch
  195
• 9 Ignition/starter switch and lock cylinder
  198
• 9.1 Removing and installing lock cylinder
  198
• 9.2 Removing and installing ignition/starter switch
  200
• 9.3 Pin assignment for ignition switch
  201
• 10 Parking aid
  202
• 10.1 General description
  202
• 10.2 Assembly overview - parking aid
  202
• 10.3 Removing and installing parking aid control unit
  203
• 10.4 Removing and installing parking aid senders
  205
• 10.5 Removing and installing parking aid warning buzzer
  206
• Lights, bulbs, switches - interior
  208
• 1 Interior lights and switches
  208
• 1.1 Removing and installing light switch E1
  208
• 1.3 Removing and installing sliding sunroof adjustment regulator E139
  209
• 1.4 Removing and installing front interior light W1
  209
• 1.5 Removing and installing window regulator switch
  210
• 1.7 Removing and installing switches in centre of dash panel
  212
• 1.8 Removing and installing door contact switch
  215
• 1.9 Removing and installing bonnet contact switch F266
  216
• 1.11 Removing and installing luggage compartment light switch F5
  216
• 1.12 Removing and installing glove compartment light W6
  217
• 1.14 Removing and installing rear reading light with interior monitoring sensor G273
  218
• 1.15 Removing and installing luggage compartment light W3, Golf/Bora
  219
• 1.16 Removing and installing luggage compartment light W3, Golf Estate/Bora Estate
  220
• 1.17 Removing and installing tank filler flap remote release switch E204
  220
• 1.18 Removing and installing rear lid handle release button E234, Bora
  221
• 1.20 Removing and installing switch to deactivate interior monitor E267
  223
• 1.21 Removing and installing operating mode change-over switch (petrol or gas) E382
  223
• 2 Immobiliser
  225
• 2.1 Renewing immobiliser control unit J362
  225
• 2.2 Removing and installing immobiliser control unit J362
  225
• 2.3 Removing and installing immobiliser reader coil D2
  225
• 2.4 Transponder
  225
• 3 Anti-theft alarm system
  226
• 3.1 Activating and deactivating anti-theft alarm
  226
• 3.2 Removing and installing interior monitoring deactivation switch E267
  227
• 3.3 Removing and installing interior monitoring sensor G273
  227
• 3.4 Removing and installing bonnet contact switch F266
  227
• 3.5 Central locking and anti-theft alarm system aerial R47
  227
• 3.6 Removing and installing anti-theft alarm H8
  228
• 4 Specified torques: lights, bulbs, switches - interior
  231
• 4.1 Specified torques: anti-theft alarm system (ATA)
  231
• Wiring
  232
• 1 Vehicle diagnosis, testing and information systems
  232
• 2 Removing and installing fuse holder and relay carrier
  233
• 2.1 Removing and installing fuse holder
  233
• 2.2 Removing and installing relay plate and 13-position relay carrier
  234
• 2.3 A-pillar coupling station
  234
• 2.4 Removing and installing fuse holder on battery
  235
• 2.5 Removing and installing protective housing for relays in engine compartment
  235
• 2.6 Removing and installing cable duct in engine compartment
  235
• 2.7 Removing and installing protective housing in plenum chamber
  237
• 2.8 Specified torques: fuse holder and relay carrier
  237
• 3 Repairs to wiring harnesses and connectors
  238