Electrical system

Chapter overview

• Self-diagnosis
  1
• 1 Vehicle diagnosis, testing and information systems
  1
• 1.1 Connecting vehicle diagnosis, testing and information system VAS 5051B
  2
• 2 Immobiliser self-diagnosis
  4
• 2.1 Performing immobiliser self-diagnosis
  5
• 2.2 Fault table
  9
• 2.3 Reading data block
  10
• 2.4 Coding immobiliser control unit J362
  12
• 3 Guided functions for immobiliser
  13
• 3.2 Online system test
  14
• 3.3 Adaptation of ignition keys
  14
• 3.4 Adaptation (matching) after changing engine control unit
  15
• 3.5 Adapting immobiliser
  15
• 4 Dash panel insert adaptation
  16
• 4.1 Adapting the dash panel insert
  17
• 4.2 Vehicle speed display adaptation
  21
• 4.3 Adapting distance travelled display
  24
• 4.4 Adaptation of distance travelled display unit
  26
• 4.5 Engine speed signal adaptation
  27
• 4.6 Adaptation of ambient temperature display unit
  28
• 4.7 Adapting selector lever position display (automatic gearbox)
  29
• 4.8 Adaptation of dash panel insert identification
  31
• 5 Tachograph self-diagnosis
  33
• 5.1 Carrying out tachograph self-diagnosis
  33
• 5.2 Fault table
  37
• 5.3 Reading data block
  37
• Starter, current supply, CCS
  41
• 1 Battery
  41
• 1.1 Fundamentals for batteries
  41
• 1.2 Types of battery
  41
• 1.3 Warning notices and safety regulations
  42
• 1.4 Battery terminal connection
  44
• 2 Checking battery
  45
• 2.1 Procedure when checking a battery
  45
• 2.2 Visual check
  45
• 2.3 Checking battery with magic eye
  46
• 2.4 Checking low maintenance battery
  47
• 2.5 Checking "no load" voltage of battery
  50
• 2.6 Battery tester with printer VAS 5097 A
  51
• 2.7 Evaluating test result
  54
• 3 Charging battery
  55
• 3.1 Battery charger VAS 5095 A
  55
• 3.2 Battery charger VAS 5900
  59
• 3.3 Totally discharged batteries
  67
• 4 Disconnecting and reconnecting battery
  69
• 4.1 Disconnecting battery
  69
• 4.2 Reconnecting battery
  69
• 5 Removing and installing battery
  71
• 5.1 Removing battery
  71
• 5.2 Installing battery
  71
• 5.3 Batteries with central gas venting
  72
• 6 Specified torques: battery
  74
• 7 Starter
  75
• 7.1 Removing and installing starter
  75
• 8 Removing and installing alternator
  78
• 8.1 4-cylinder petrol engine
  78
• 8.2 5-cylinder diesel engine
  79
• 8.3 4-cylinder diesel engine
  80
• 8.4 Checking V-belt and poly V-belt
  82
• 8.5 Removing and installing poly V-belt
  82
• 8.6 Securing B+ and D+ wires to alternator
  85
• 8.7 Alternator carbon brushes
  86
• 8.8 Removing and installing poly V-belt pulley on alternator
  86
• 9 Cruise control system (CCS)
  87
• 9.1 Cruise control system for vehicles with direct-injection diesel engine
  87
• 9.2 Assembly overview - cruise control system
  87
• 9.3 Removing and installing cruise control system switch E45
  88
• Gauges, instruments
  90
• 1 Dash panel insert
  90
• 1.1 Removing and installing dash panel insert
  90
• 1.2 Pin assignment of multi-pin connectors at dash panel insert
  94
• 1.3 Installation position of bulbs for illumination and warning lamps
  97
• 1.4 Dash panel insert warning lamp symbols
  99
• 2 Tachograph instrument cowling with tachograph
  101
• 2.1 Pin assignment of multi-pin connectors at tachograph instrument cowling and tachograph
  101
• 2.2 Installation position of bulbs for illumination and warning lamps
  105
• 2.3 Tachograph instrument cowling warning lamp symbols
  107
• Communication
  108
• 1 Radio systems
  108
• 1.1 Radio systems with 2 loudspeakers
  108
• 1.2 Radio systems with 4 loudspeakers
  109
• 1.3 Removing and installing radio
  109
• 1.4 Activating anti-theft coding on radio
  111
• 1.5 Removing and installing front loudspeaker
  112
• 1.6 Removing and installing rear loudspeakers
  113
• 2 Aerial system
  114
• 2.1 Removing and installing roof aerial
  114
• Windscreen wash/wipe system
  116
• 1 Windscreen wiper system
  116
• 1.1 Assembly overview - windscreen wiper system
  116
• 1.2 Setting park position
  117
• 1.3 Adjusting wiper blade park position
  117
• 1.4 Removing and installing wiper rubber
  117
• 2 Headlight washer system
  118
• 2.1 Assembly overview - headlight washer system
  118
• 2.2 Adjusting spray jets
  118
• 3 Window washer system
  119
• 3.1 Assembly overview - windscreen washer system
  119
• 3.2 Removing washer jet
  119
• 3.3 Adjusting spray jet
  120
• 3.4 Removing reservoir
  120
• 4 Hose repair
  121
• 4.1 General description
  121
• 4.2 Repairing smooth pipe
  121
• 4.3 Repairing corrugated pipe
  121
• Lights, bulbs, switches - exterior
  123
• 1 Headlights and fog lights
  123
• 1.1 Assembly overview - headlight unit
  123
• 1.2 Removing and installing headlight insert
  125
• 1.3 Removing and installing headlight bulbs
  126
• 1.4 Removing and installing lens
  127
• 1.5 Adjusting headlights
  127
• 2 Front turn signals
  129
• 2.1 Removing and installing turn signal indicator housing
  129
• 2.2 Removing and installing front turn signal bulb
  130
• 2.3 Removing and installing side-mounted turn signals
  131
• 3 Additional brake light
  132
• 3.1 Removing and installing additional brake light
  132
• 4 Number plate light
  133
• 4.1 Removing and installing number plate light on panel van
  133
• 5 Steering column switch
  134
• 5.1 Assembly overview - steering column switch
  134
• 5.2 Pin assignment on steering column switch
  138
• 5.3 Removing and installing steering lock housing
  138
• 6 Pneumatic headlight range control
  140
• 6.1 Vacuum system (block diagram)
  140
• 6.2 Checking adjustment range
  140
• 6.3 Checking vacuum values
  141
• 7 Removing and installing tail lights
  142
• 7.1 Removing and installing van tail light
  142
• 7.2 Removing and installing drop-side tail light
  144
• 8 Removing and installing side marker lights
  145
• 8.1 Removing and installing front side marker light
  145
• 8.2 Removing and installing centre side marker light
  146
• 8.3 Removing and installing rear side marker light
  147
• 9 Ignition/starter switch and lock cylinder
  148
• 9.1 Removing and installing ignition/starter switch
  148
• 9.2 Pin assignment of multi-pin connector at ignition/starter switch
  150
• 9.3 Removing and installing lock cylinder
  150
• Lights, bulbs, switches - interior
  153
• 1 Immobiliser
  153
• 1.1 Removing and installing immobiliser
  153
• 1.2 Removing and installing immobiliser reader coil D2
  153
• 1.3 Transponder
  154
• 2 Removing and installing switches in dash panel
  155
• 2.1 Removing switches from dash panel insert trim
  155
• 2.2 Removing front interior light with reading light
  157
• 2.3 Removing rear interior light/load compartment
  158
• Wiring
  159
• 1 Relay plate
  159
• 1.1 Removing relay plate with fuse carrier
  159
• 1.2 Auxiliary relay carrier under driver seat
  161
• 2 Wiring harness and connector repairs
  162
• 2.1 Notes on safety
  162
• 2.2 General notes concerning repairs to vehicle electrical system
  162
• 2.3 Instructions concerning wiring harness and connector repairs
  162
• 2.4 Supplementary notes on repair of CAN bus wiring
  163
• 2.5 Wiring harness repair set V.A.S 1978
  163
• 2.6 Release tool set VAS 1978/35 for primary and secondary locking elements
  164
• 3 Repairing wiring harness sections
  166
• 3.1 Assembly overview - front end wiring harness section
  166
• 3.2 Front end wiring harness section connections
  167
• 3.3 Wiring assignment at separating point for front end wiring harness section
  173
• 3.4 Front wiring harness repair procedure
  174
• 3.5 Assembly overview - rear end wiring harness section
  177
• 3.6 Rear end wiring harness section connections
  178
• 3.7 Wiring assignment at separating point for rear end wiring harness section
  180
• 3.8 Rear wiring harness repair procedure
  181
• 4 Renewal of aerial wiring
  185
• 4.1 General description
  185
• 4.2 Assembly overview - aerial wire
  185
• 4.3 Installing a new aerial wire
  185
• 5 Crimping pliers V.A.S 1978/9
  187
• 5.1 Fitting tool head
  187
• 5.2 Stripping
  188
• 5.3 Crimping
  189
• 6 Optical fibre lines (OFL)
  190
• 7 Airbag and belt tensioner wiring harness
  191