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Electrical system

For Lupo / Lupo 3L

Original Volkswagen repair manual


15,68 €7% VAT incl.

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Language: English

Digital PDF file

3.777 KB

187 Sites

Detailed technical data

Immediately readable

This repair manual contains: Battery, Disconnecting and connecting battery, Specified torques: starter, Dash panel insert, Service interval display, windscreen wiper system, Washer fluid line hose couplings, Hose repair, Headlight with gas discharge bulb, Fog lights, Lights and switches in engine compartment, Anti-theft alarm (ATA) and Removing and installing relay carrier, coupling station and fuse holder. Show more
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Repair manual Lupo / Lupo 3L Electrical system PDF download has the following content:

Chapter overview

  • Starter, current supply, CCS
    1
  • 1 Battery
    1
  • 1.1 Types of battery
    1
  • 1.2 Warning notices and safety regulations
    1
  • 1.3 Battery terminal connection
    1
  • 2 Checking battery
    2
  • 3 Charging battery
    3
  • 4 Disconnecting and connecting battery
    4
  • 5 Removing and installing battery
    8
  • 5.1 Removing and installing battery, vehicles with battery in engine compartment
    8
  • 5.2 Removing and installing battery, models with battery in luggage compartment
    11
  • 6 Battery isolator
    16
  • 6.1 Overview of fitting locations
    16
  • 6.2 Safety precautions when working on battery isolator
    16
  • 6.3 Removing and installing battery isolator
    17
  • 7 Specified torques: battery
    19
  • 8 Starter motor
    20
  • 8.1 Checking starter B
    20
  • 8.2 Removing and installing starter, automatic gearbox
    20
  • 8.3 Removing and installing starter, manual gearbox
    22
  • 9 Specified torques: starter
    27
  • 9.1 Automatic gearbox except 3L and FSI models
    27
  • 9.2 Manual gearbox
    27
  • 10 Alternator
    29
  • 10.1 Checking alternator C
    29
  • 10.2 Checking poly V-belt
    29
  • 10.3 Alternator ► 04.99
    29
  • 10.4 Alternator 05.99 ►
    30
  • 10.5 4-cylinder injection engine (except vehicles with engine codes AHT and AVY)
    31
  • 10.6 4-cylinder fuel injected engine, engine code AHT
    36
  • 10.7 4-cylinder fuel injected engine, engine code AVY
    41
  • 10.8 3-cylinder diesel engine
    43
  • 10.9 4-cylinder diesel engine
    45
  • 10.10 Renewing poly V-belt pulley on alternator
    46
  • 10.11 Installing poly V-belt pulley with freewheel
    48
  • 11 Specified torques: alternator
    50
  • 11.1 General specified torques for all vehicles
    50
  • 11.2 Specified torques, 4-cyl. injection engine
    50
  • 11.3 Specified torques for 4-cyl. injection engine, engine code AHT
    51
  • 11.4 Specified torques for 4-cyl. injection engine, engine code AVY
    51
  • 11.5 Specified torques 3-cyl. diesel engine
    52
  • 11.6 Specified torques 4-cyl. diesel engine
    52
  • Gauges, instruments
    53
  • 1 Dash panel insert
    53
  • 1.1 Renewing dash panel insert
    53
  • 1.2 Removing and installing dash panel insert
    54
  • 1.3 Description of back of dash panel insert
    55
  • 1.4 Pin assignment of connectors on dash panel insert
    57
  • 1.5 Warning lamp symbols and instruments in dash panel insert
    59
  • 2 Service interval display
    60
  • 2.1 Resetting service interval display
    60
  • Windscreen wash/wipe system
    61
  • 1 windscreen wiper system
    61
  • 1.1 Removing and installing windscreen wiper system
    61
  • 1.2 Adjusting wiper blade park position
    67
  • 1.3 Checking and adjusting angle of incidence
    67
  • 1.4 Removing and installing wiper rubber
    68
  • 1.5 Removing and installing joint-free wipers
    69
  • 1.6 Removing and installing joint-free wiper rubber (manufacturer: Bosch)
    70
  • 2 Windscreen washer system
    72
  • 2.1 Assembly overview - windscreen washer system
    72
  • 2.2 Removing and installing windscreen washer system reservoir
    73
  • 2.3 Removing and installing windscreen and rear window washer pump V59
    74
  • 2.4 Removing and installing windscreen washer system spray jets
    74
  • 2.5 Adjusting windscreen washer system spray jets
    74
  • 3 Rear window wiper system
    75
  • 3.1 Assembly overview - rear window wiper system
    75
  • 3.2 Removing and installing rear window wiper
    75
  • 3.3 Adjusting rear window wiper park position
    77
  • 3.4 Renewing wiper rubber blade
    78
  • 3.5 Removing and installing aerodynamic wipers
    78
  • 4 Rear window washer system
    80
  • 4.1 Assembly overview - rear window washer system
    80
  • 4.2 Renewing spray jet
    81
  • 4.3 Adjusting spray jet
    81
  • 5 Headlight washer system
    82
  • 5.1 Assembly overview - headlight washer system
    82
  • 5.2 Removing and installing headlight washer system pump V11
    83
  • 5.3 Removing and installing spray jet pop-up cylinders
    84
  • 5.4 Removing and installing spray jet retainer
    84
  • 5.5 Removing and installing headlight washer system reservoir
    85
  • 5.6 Adjusting windscreen washer system spray jets
    85
  • 5.7 Bleeding headlight washer system
    85
  • 6 Washer fluid line hose couplings
    86
  • 7 Hose repair
    87
  • 8 Specified torques: Windscreen wash/wipe system
    88
  • Lights, bulbs, switches - exterior
    89
  • 1 Headlights
    89
  • 1.1 Assembly overview - headlight
    89
  • 1.2 Removing and installing headlight
    90
  • 1.3 Renewing headlight bulbs
    91
  • 1.4 Renewing headlight bulbs, Lupo 16V
    92
  • 1.5 Renewing headlight bulbs, Lupo TDI
    94
  • 1.6 Removing and installing headlight range control motor
    96
  • 1.7 Repairing headlight retaining tabs
    97
  • 1.8 Headlight conversion for driving on left/right
    99
  • 1.9 Adjusting headlights
    101
  • 2 Headlight with gas discharge bulb
    102
  • 2.1 Assembly overview, headlights with gas discharge bulb
    103
  • 2.2 Removing and installing headlight
    104
  • 2.3 Renewing gas discharge headlight bulb
    105
  • 2.5 Removing and installing gas discharge bulb control unit
    114
  • 2.7 Coding headlight range control unit J431
    116
  • 2.8 Repairing headlight retaining tabs
    117
  • 2.9 Adjusting headlight with gas discharge bulb
    117
  • 3 Fog lights
    118
  • 3.1 Removing and installing fog light
    118
  • 3.2 Renewing fog light bulb
    118
  • 3.3 Adjusting fog lights
    119
  • 4 Front turn signals
    120
  • 4.1 Removing and installing front turn signal
    120
  • 4.2 Renewing turn signal bulb
    121
  • 5 Turn signal repeaters
    123
  • 5.1 Removing and installing turn signal repeaters
    123
  • 6 Tail lights
    124
  • 6.1 Assembly overview - tail light
    124
  • 6.2 Removing and installing tail light cluster
    124
  • 6.3 Removing and installing tail light bulb carrier
    125
  • 6.4 Specified torques: tail light cluster
    125
  • 7 Number plate light
    126
  • 7.1 Removing and installing number plate light
    126
  • 8 Additional brake lights
    127
  • 8.1 Lupo with steel rear lid
    127
  • 8.2 Lupo with alloy rear lid (Lupo 3L und Lupo FSI)
    129
  • 8.3 Lupo with steel rear lid and rear spoiler (Lupo GTI)
    131
  • 9 Steering column switch and ignition/starter switch
    134
  • 9.1 Assembly overview - steering column
    134
  • 9.2 Removing and installing steering column switch
    135
  • 9.3 Pin assignment on steering column switch
    137
  • 9.4 Removing and installing steering lock housing
    137
  • 9.5 Removing and installing lock cylinder
    139
  • 9.6 Removing and installing ignition/starter switch
    140
  • 9.7 Pin assignment for ignition switch
    140
  • Lights, bulbs, switches - interior
    141
  • 1 Interior lights and switches
    141
  • 1.1 Removing and installing switch to deactivate interior monitor E267
    141
  • 2 Lights and switches in engine compartment
    142
  • 2.1 Removing and installing engine compartment light W27
    142
  • 2.2 Removing and installing anti-theft alarm and vermin repellent system contact switch F120
    142
  • 3 Lights and switches in dash panel, vehicles ► 04.00
    143
  • 3.1 Assembly overview - lights and switches in dash panel
    143
  • 3.2 Removing and installing light switch E1
    143
  • 3.4 Removing and installing switches in centre of dash panel
    145
  • 4 Lights and switches in dash panel, vehicles 05.00 ►
    147
  • 4.1 Assembly overview - switches in dash panel
    147
  • 4.2 Removing and installing light switch E1
    147
  • 4.4 Removing and installing switches in centre of dash panel
    148
  • 4.5 Removing and installing hazard warning light switch E3
    149
  • 4.7 Removing and installing key-operated switch to deactivate front passenger side airbag E224
    151
  • 5 Lights and switches in front doors
    152
  • 5.1 Removing and installing switch module for driver side window regulator
    152
  • 5.2 Removing and installing front right window regulator switch E41
    153
  • 5.3 Removing and installing Central locking SAFELOCK function warning lamp K133
    154
  • 5.4 Removing and installing door contact switch
    155
  • 6 Lights and switches in luggage compartment
    156
  • 6.1 Removing and installing luggage compartment light W3
    156
  • 6.2 Components - rear lid lock
    156
  • 7 Lights and switches in roof trim
    157
  • 7.1 Front interior light W
    157
  • 8 Horn
    158
  • 8.1 Removing and installing horn/dual tone horn H1
    158
  • 8.2 Removing and installing treble horn H2 and bass horn H7
    159
  • 9 Immobiliser
    160
  • 9.1 Immobiliser control unit J362
    160
  • 9.2 Removing and installing immobiliser reader coil D2
    162
  • 9.3 Ignition key
    162
  • 10 Anti-theft alarm (ATA)
    164
  • 10.1 Activating and deactivating anti-theft alarm
    164
  • 10.2 Removing and installing switch to deactivate interior monitor E267
    165
  • 10.3 Removing and installing ultrasonic sensor for ATAS G209
    165
  • 10.4 Central locking and anti-theft alarm system aerial R47
    165
  • 10.5 Alarm horn H12
    165
  • Wiring
    167
  • 1 Vehicle diagnosis, testing and information systems
    167
  • 1.1 Connecting vehicle diagnosis, testing and information system VAS 5051A
    167
  • 2 Removing and installing relay carrier, coupling station and fuse holder
    170
  • 2.1 Removing and installing relay carrier
    170
  • 2.2 Removing and installing coupling station below relay carrier
    172
  • 2.3 Removing and installing fuse holder in front left footwell
    173
  • 3 Select Control units
    176
  • 3.1 Data bus diagnostic interface J533
    176
  • 3.2 Central locking and anti-theft alarm system control unit J379
    176
  • 3.3 Voltage stabiliser J532
    179
  • 4 Wiring harness and connector repairs
    181
Manufacturer's designation Electrical system
Manufacturer Volkswagen
Suitable for Lupo (1998 - 2006) / Lupo 3L (1999 - 2006)
Suitable car types 6X, 6E
Category Reparaturanleitung

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