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
• 5 Removing and installing battery
  11
• 5.1 Petrol engine vehicles with battery installed in engine compartment
  11
• 5.2 Diesel engine vehicles with battery installed in engine compartment
  12
• 5.3 Vehicles with an additional battery
  18
• 5.4 Vehicles with battery in luggage compartment
  20
• 6 Specified torques: battery
  21
• 6.1 Specified torques: battery in engine compartment
  21
• 6.2 Specified torques: additional battery/battery in luggage compartment
  21
• 7 Pyrotechnical battery isolator
  22
• 7.1 Overview of fitting locations
  22
• 7.2 Safety precautions when working on pyrotechnical battery isolator
  23
• 7.3 Disposal of pyrotechnical battery isolation units
  23
• 7.4 Removing and installing pyrotechnical battery isolator
  23
• 8 Specified torques: pyrotechnic battery isolator
  26
• 8.1 Specified torques: main fuse box
  26
• 9 Jump start point with suppression filter C24
  27
• 9.1 Overview of fitting locations
  27
• 9.2 Removing and installing jump start point with suppression filter C24
  27
• 10 Specified torques: jump start point
  29
• 11 Starter
  30
• 11.1 Checking starter B
  30
• 11.2 Removing and installing starter, automatic gearbox
  30
• 11.3 Removing and installing starter, dual clutch gearbox (DSG)
  38
• 11.4 Removing and installing starter, manual gearbox
  45
• 12 Specified torques: starter
  65
• 13 Starter, vehicles with 1.8 l TSI engine and manual gearbox
  66
• 13.1 Assembly overview
  66
• 14 Alternator
  71
• 14.1 Securing B+ (battery positive) wire to alternator
  71
• 14.2 Checking poly V-belt
  71
• 14.3 Checking alternator C
  72
• 14.4 Alternator, 1.4 l TSI engine
  72
• 14.5 Alternator, 1.8 l TSI engine
  77
• 14.6 Alternator, 1.6 l injection engine
  80
• 14.7 Alternator, 1.6 l FSI engine
  86
• 14.8 Alternator, 2.0 l FSI engine
  91
• 14.9 Alternator, 2.0 l FSI turbocharged engine
  97
• 14.10 Alternator, 3.6 l FSI engine and 3.2 l injection engine
  103
• 14.11 Alternator, 1.6 l TDI engine
  108
• 14.12 Alternator, 1.9 l and 2.0 l TDI engine (2 valves per cylinder)
  112
• 14.13 Alternator, 2.0 l TDI engine (4 valves per cylinder)
  118
• 14.14 Alternator, 2.0 l TDI common rail injection engine
  124
• 14.15 Removing and installing poly V-belt pulley on alternator
  128
• 14.16 Voltage regulator for alternator
  132
• 15 Specified torques: alternator
  135
• 15.1 General specified torques for all vehicles
  135
• 15.2 1.6 l injection engine and 2.0 l FSI engine
  135
• 15.3 2.0 l FSI turbocharged engine
  136
• 15.4 3.6 l FSI engine and 3.2 l injection engine
  137
• 15.5 1.9 l and 2.0 l TDI engine
  138
• 16 Cruise control system (CCS)
  140
• 16.1 Activating and deactivating cruise control system (CCS)
  140
• 17 Adaptive cruise control (ACC)
  141
• 17.1 Assembly overview
  141
• 17.2 Removing and installing adaptive cruise control button E357
  142
• 17.3 Removing and installing adaptive cruise control unit J428
  142
• 17.4 Calibrating adaptive cruise control sensor G550
  143
• 17.5 Initialising adaptive cruise control
  143
• Gauges, instruments
  145
• 1 Dash panel insert
  145
• 1.1 Adapting/renewing dash panel insert
  145
• 1.2 Removing and installing dash panel insert
  146
• 1.3 Dash panel insert final control diagnosis
  146
• 1.4 Description of back of dash panel insert
  147
• 1.5 Pin assignment of connectors on dash panel insert
  147
• 1.6 Warning lamp symbols in dash panel insert
  148
• 2 Service interval display
  150
• 2.1 Resetting service interval display
  150
• Windscreen wash/wipe system
  151
• 1 Windscreen wiper system
  151
• 1.1 Deactivating APP function of wiper motor
  151
• 1.2 Removing and installing windscreen wiper system
  152
• 1.3 Removing and installing wiper arms
  156
• 1.4 Adjusting wiper blade park position
  157
• 1.5 Removing and installing aerodynamic wipers
  158
• 1.6 Removing and installing rain and light sensor G397
  160
• 2 Windscreen washer system
  163
• 2.1 Assembly overview - windscreen washer system
  163
• 2.2 Removing and installing washer fluid reservoir
  164
• 2.3 Removing and installing washer pump V5 or windscreen and rear window washer pump V59
  169
• 2.4 Removing and installing windscreen washer fluid level sender G33
  170
• 2.5 Removing and installing windscreen washer system spray jets
  170
• 2.6 Adjusting windscreen washer system spray jets
  171
• 3 Rear window wiper system
  172
• 3.1 Assembly overview - rear window wiper system
  172
• 3.2 Removing rear window wiper
  173
• 3.3 Adjusting rear window wiper park position
  175
• 3.4 Removing and installing aerodynamic wipers
  175
• 4 Rear window washer system
  177
• 4.1 Assembly overview - rear window washer system
  177
• 4.2 Renewing spray jet
  178
• 4.3 Adjusting spray jet
  178
• 5 Headlight washer system
  179
• 5.1 Assembly overview - headlight washer system
  179
• 5.2 Removing and installing headlight washer system pump V11
  181
• 5.3 Removing and installing pop-up cylinder with spray jet
  181
• 5.4 Removing and installing spray jet retainer
  182
• 5.5 Adjusting spray jets
  182
• 5.6 Bleeding headlight washer system
  183
• 5.7 Adapting headlight washer system
  183
• 6 Washer fluid line hose couplings
  184
• 6.1 Headlight washer system
  184
• 7 Hose repair
  185
• 8 Specified torques: window wash/wipe system
  186
• 8.1 Specified torques for windscreen wash/wipe system
  186
• 8.2 Specified torques for rear window wash/wipe system
  186
• 8.3 Specified torques for headlight washer system
  186
• Lights, bulbs, switches - exterior
  187
• 1 Headlights
  187
• 1.1 Assembly overview - headlight
  187
• 1.2 Removing and installing headlight
  189
• 1.3 Adjusting headlight installation position
  191
• 1.4 Renewing headlight bulbs, headlight manufacturer Hella
  192
• 1.5 Renewing headlight bulbs, headlight manufacturer Valeo
  200
• 1.8 Repairing headlight retaining tabs
  212
• 1.9 Converting headlights to drive on the left or the right (manufactured by Hella)
  216
• 1.11 Adjusting headlights
  222
• 2 Headlights with gas discharge bulb and cornering light
  223
• 2.1 Assembly overview - headlight with gas discharge bulb and cornering lights
  224
• 2.2 Removing and installing headlight
  225
• 2.3 Adjusting headlight installation position
  225
• 2.4 Renewing bulbs of headlight with gas discharging bulb and cornering light
  226
• 2.5 Headlight range control motor
  234
• 2.6 Dynamic cornering light control motor
  236
• 2.7 Swivel module position sensor
  236
• 2.8 Dipped beam screen
  236
• 2.9 Power output module for headlight
  237
• 2.10 Removing and installing gas discharge bulb control unit
  239
• 2.11 Cornering light and headlight range control unit J745
  240
• 2.12 Vehicle level sender
  241
• 2.13 Repairing headlight retaining tabs
  242
• 2.14 Converting headlights for use when driving on the left or right
  242
• 2.15 Adjusting headlights
  245
• 3 Fog lights
  246
• 3.1 Assembly overview - fog lights
  246
• 3.2 Removing and installing fog light
  247
• 3.3 Removing and installing fog light bulb
  247
• 3.4 Checking fog lights
  248
• 3.5 Adjusting fog lights
  248
• 4 Front turn signals
  249
• 4.1 Removing and installing front turn signal
  249
• 4.2 Removing and installing turn signal bulb
  250
• 4.3 Checking front turn signal
  251
• 5 Bulb for mirror turn signal and entry light in exterior mirror
  252
• 5.1 Turn signal repeater bulb
  252
• 5.2 Entry light in exterior mirror
  253
• 6 Tail lights
  256
• 6.1 Tail light in side panel (saloon)
  256
• 6.2 Tail light cluster in rear lid (saloon)
  259
• 6.3 Tail light cluster in side panel (estate)
  262
• 6.4 Tail light in rear lid (Variant)
  266
• 6.5 Tail lights for Canada and USA
  269
• 7 Number plate light
  270
• 7.1 Removing and installing bolted number plate light X (saloon)
  270
• 7.2 Removing and installing bolted number plate light X (estate)
  271
• 7.3 Clipped number plate light X
  271
• 7.4 Checking number plate light X
  272
• 8 Additional brake lights
  273
• 8.1 Tools
  273
• 8.2 Removing and installing high-level brake light bulb M25 (saloon)
  274
• 8.3 Removing and installing high-level brake light bulb M25 (Variant)
  274
• 8.4 Removing and installing high-level brake light bulb M25 (Variant R36)
  275
• 8.5 Checking high-level brake light bulb M25
  276
• 9 Steering column switch up to 10/09
  277
• 9.1 Assembly overview - steering column switch
  277
• 9.2 Removing and installing steering column switch
  278
• 9.3 Steering column electronics control unit J527
  279
• 9.4 Airbag coil connector and return ring with slip ring F138
  282
• 9.5 Segment sender for steering angle sensor
  283
• 9.6 Steering column combination switch E595
  283
• 10 Steering column switch, vehicles from 11/09
  286
• 10.1 General description
  286
• 10.2 Assembly overview - steering column switch
  286
• 10.3 Removal and installation sequence of components of steering column switch
  287
• 10.4 Steering column electronics control unit J527
  288
• 10.5 Steering column combination switch E595
  292
• 10.6 Steering column switch carrier
  293
• 11 Ignition/starter switch and lock cylinder
  298
• 11.1 Ignition/starter switch
  298
• 11.2 Lock cylinder
  298
• 12 Parking aid
  299
• 12.1 General description
  299
• 12.2 Assembly overview - parking aid
  300
• 12.3 Parking aid control unit J446 and park assist steering control unit J791
  301
• 12.4 Front parking aid senders
  303
• 12.5 Rear parking aid senders
  304
• 12.6 Parking aid warning buzzer
  305
• 12.7 Parking aid button E266
  306
• 12.8 Bonding sender retainer for parking aid and park assist steering in cases of repair
  306
• 13 Park assist steering (PAS)
  311
• 13.1 General description
  311
• 13.2 Assembly overview of park assist steering
  312
• 13.3 Park assist steering control unit J791
  314
• 13.4 Front parking aid sender and park assist steering sender
  314
• 13.5 Park assist steering button E581
  317
• 13.6 Front parking aid warning buzzer H22
  317
• 13.7 Rear parking aid warning buzzer H15 (vehicles with park assist steering)
  319
• 14 Entry and start authorisation
  320
• 14.1 General description
  320
• 14.2 Emergency starting when communication between ID sender and control unit is defective
  321
• 14.3 Electronic ignition lock D9
  321
• 14.4 Convenience system central control unit J393
  322
• 14.5 Entry and start authorisation aerials and sensors
  323
• 14.6 Checking entry and start system aerials and sensors
  331
• 14.7 Adapting entry and start authorisation functions
  335
• 15 Specified torques: lights, bulbs, switches - exterior
  336
• 15.1 Specified torques: headlights
  336
• 15.2 Specified torques: fog lights
  336
• 15.3 Specified torques: tail light cluster in side panel (saloon)
  336
• 15.4 Specified torques: tail light cluster in side panel (estate)
  336
• 15.5 Specified torques: tail light cluster in rear lid (saloon)
  336
• 15.6 Specified torques: tail light cluster in rear lid (estate)
  336
• 15.7 Specified torques: steering column switch unit
  336
• 16 Reversing camera system
  337
• 16.1 General description
  337
• 16.2 Assembly overview - reversing camera system
  337
• 16.3 Removing and installing reversing camera
  338
• 16.4 Reversing camera system control unit
  341
• 16.5 Calibrating reversing camera system
  342
• 16.6 Renewing video cable
  347
• Lights, bulbs, switches - interior
  349
• 1 Interior lights and switches
  349
• 1.2 Footwell lights
  350
• 2 Lights and switches in engine compartment
  352
• 2.1 Removing and installing bonnet contact switch F266
  352
• 3 Lights and switches in dash panel
  353
• 3.1 Removing and installing light switch E1
  353
• 3.3 Removing and installing electromechanical parking brake button E538
  354
• 3.5 Removing and installing glove compartment light W6
  357
• 3.6 Removing and installing glove compartment light switch E26
  359
• 3.7 Removing and installing hazard warning light switch E3
  359
• 4 Lights and switches in front doors
  361
• 4.1 Removing and installing driver side switch element
  361
• 4.2 Removing and installing driver side interior locking button for central locking system E308
  362
• 4.3 Removing and installing mirror adjustment switch E43
  363
• 4.4 Removing and installing remote release button for fuel filler flap and rear lid E233
  364
• 4.6 Central locking SAFELOCK function warning lamp K133
  366
• 4.7 Removing and installing window regulator switch in front passenger door E107
  367
• 4.8 Front left entry light W31 and front right entry light W32
  367
• 4.9 Components - front door locks
  369
• 5 Lights and switches in rear doors
  371
• 5.1 Removing and installing rear window regulator switch E52 and E54
  371
• 5.2 Rear left entry light W33 and rear right entry light W34
  372
• 5.3 Components - rear door locks
  372
• 6 Lights and switches in luggage compartment
  373
• 6.1 Luggage compartment light W3
  373
• 6.2 Rear lid lock unit F256
  374
• 7 Lights and switches in roof trim
  375
• 7.1 Front interior light
  375
• 7.2 Rear interior and reading lights
  378
• 7.4 Garage door opener
  381
• 7.5 Automatic anti-dazzle interior mirror Y7
  381
• 8 Lights and switches in centre console
  382
• 8.1 Removing and installing switches in centre console
  382
• 8.2 Removing and installing front ashtray illumination bulb
  383
• 8.3 Removing and installing cigarette lighter U1
  383
• 8.5 Removing and installing storage compartment illumination bulb L120
  384
• 8.6 Removing and installing DC/AC converter with socket, 12 V-230 V U13
  386
• 9 Horn
  389
• 9.1 Removing and installing treble horn H2 and bass horn H7
  389
• 9.2 Checking treble horn H2 and bass horn H7
  389
• 9.3 Horn plate H
  389
• 10 Immobiliser
  391
• 10.1 Immobiliser control unit J362
  392
• 10.2 Immobiliser reader unit D1
  392
• 10.3 Electronic ignition lock D9
  392
• 10.4 Electronic steering column lock (ESL) control unit J764
  394
• 10.5 Ignition key
  396
• 10.6 Online system test
  398
• 11 Anti-theft alarm system (ATAS)
  400
• 11.1 Assembly overview - anti-theft alarm (ATA)
  401
• 11.2 Activating and deactivating anti-theft alarm
  402
• 11.4 Interior monitoring sensor G273
  403
• 11.5 Interior monitor send and receive module 1 G303
  403
• 11.6 Vehicle inclination sender G384
  405
• 11.7 Central locking and anti-theft alarm system aerial R47
  405
• 11.8 Adapting alarm delay on opening driver door
  406
• 11.9 Alarm horn H12
  406
• 12 Taxi equipment
  409
• 12.1 Onboard supply control unit J519 for special vehicles
  409
• 12.2 Special vehicle control unit J608
  409
• 13 Specified torques: lights, bulbs and switches - interior
  411
• 13.1 Torque settings: alarm horn H12
  411
• 13.2 Specified torques: treble horn H2
  411
• 13.3 Specified torques: bass horn H7
  411
• Wiring
  412
• 1 Vehicle diagnosis, testing and information systems
  412
• 2 Fuse holder
  413
• 2.1 Removing and installing fuse holder
  413
• 3 Relay carriers
  415
• 3.1 Removing and installing relay carrier on left of dash panel
  415
• 3.2 Removing and installing onboard supply control unit J519
  417
• 4 Electronics boxes
  419
• 4.1 Removing and installing electronics box on left side of engine compartment
  419
• 5 Main fuse box
  423
• 5.1 Removing and installing main fuse holder
  423
• 6 Control units
  425
• 6.1 On-board supply control unit J519
  425
• 6.2 Data bus diagnostic interface J533
  430
• 6.3 Convenience system central control unit J393
  433
• 6.4 Driver door control unit J386
  439
• 6.5 Front passenger door control unit J387
  440
• 6.6 Rear left door control unit J388
  442
• 6.7 Rear right door control unit J389
  443
• 6.8 Trailer detector control unit J345
  445
• 6.9 Special vehicle control unit J608
  447
• 6.10 Electronic steering column lock (ESL) control unit J764
  450
• 7 Specified torques: wiring
  451
• 7.1 Specified torques: fuse holder
  451
• 7.2 Specified torques: electronics box on left side of engine compartment
  451
• 7.3 Specified torques: convenience system central control unit J393
  451
• 7.4 Specified torques: special vehicle control unit J608
  451
• 8 Repairs to wiring harnesses and connectors
  452