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
  2
• 1.4 Fitting battery terminal clamps
  4
• 2 Checking battery
  5
• 2.1 Procedure when checking a battery
  5
• 2.2 Visual inspection
  5
• 2.3 Checking battery with magic eye
  6
• 2.4 Checking low maintenance battery
  7
• 2.5 Checking "no load" voltage of battery
  10
• 2.6 Battery tester with printer VAS 5097 A
  11
• 2.7 Evaluating test result
  14
• 3 Charging battery
  15
• 3.1 Battery charger VAS 5095 A
  15
• 3.2 Battery charger VAS 5900
  19
• 3.3 Totally discharged batteries
  27
• 4 Disconnecting and connecting battery
  29
• 4.1 Disconnecting battery
  29
• 4.2 Connecting battery:
  29
• 5 Removing and installing battery
  31
• 5.1 Battery in engine compartment
  31
• 5.2 Second battery under driver seat
  33
• 6 Specified torques: battery
  36
• 7 Starter motor
  37
• 7.1 Removing and installing starter motor
  37
• 8 Specified torques: starter
  42
• 9 Alternator with V-belt
  43
• 9.1 4-cylinder petrol engine
  43
• 9.2 4-cylinder diesel engine
  45
• 9.3 Checking and adjusting V-belt tension
  48
• 10 Alternator with poly V-belt
  51
• 10.1 4-cyl. engine with 90 A alternator ► 04.99
  51
• 10.2 4-cylinder engine with 90 A alternator 05.99 ►
  57
• 10.3 4-cyl. engine with 120 A alternator ► 04.99
  62
• 10.4 4-cylinder engine with 120 A alternator 05.99 ►
  68
• 10.5 4-cylinder engine with air conditioner compressor or 2nd alternator ► 04.99
  74
• 10.6 4-cylinder engine with air conditioner compressor or 2nd alternator 05.99 ►
  79
• 10.7 5-cylinder engine without air conditioner or 2nd alternator ► 04.99
  85
• 10.8 5-cylinder engine without air conditioner or 2nd alternator 05.99 ►
  88
• 10.9 5-cyl. engines with air conditioning or 2nd alternator/hydraulic pump ► 04.99
  90
• 10.10 5-cyl. engines with air conditioning or 2nd alternator/hydraulic pump 05.99 ►
  93
• 10.11 6-cylinder injection engine ► 04.99
  96
• 10.12 6-cylinder injection engine 05.99 ►
  99
• 10.13 Compact alternator with poly V-belt drive ► 04.99
  102
• 10.14 Compact alternator with poly V-belt drive 05.99 ►
  104
• 10.15 Renewing poly V-belt pulley without freewheel on alternator
  106
• 10.16 Renewing poly V-belt with freewheel
  107
• 11 Repairing alternator
  109
• 11.1 65 A - Valeo version with poly V-belt drive
  109
• 11.2 90 A - Bosch version with poly V-belt drive
  113
• 11.3 70 A, 90 A and 120 A alternator with poly V-belt
  117
• 12 Specified torques: alternator
  120
• 12.1 General torque settings
  120
• 12.2 Specified torques: alternator with V-belt
  120
• 12.3 4-cyl. engine with 90 A alternator ► 04.99
  121
• 12.4 4-cylinder engine with 90 A alternator 05.99 ►
  121
• 12.5 4-cyl. engine with 120 A alternator ► 04.99
  121
• 12.6 4-cylinder engine with 120 A alternator 05.99 ►
  121
• 12.7 4-cylinder engine with air conditioner compressor or 2nd alternator ► 04.99
  121
• 12.8 4-cylinder engine with air conditioner compressor or 2nd alternator 05.99 ►
  122
• 12.9 5-cylinder engine without air conditioner or 2nd alternator ► 04.99
  122
• 12.10 5-cylinder engine without air conditioner or 2nd alternator 05.99 ►
  122
• 12.11 5-cyl. engine with air conditioning or 2nd alternator/hydraulic pump ► 04.99 . . . . .
  122
• 12.12 5-cyl. engine with air conditioning or 2nd alternator/hydraulic pump 05.99 ► . . . . .
  122
• 12.13 6-cylinder injection engine ► 04.99
  123
• 12.14 6-cylinder injection engine 05.99 ►
  123
• 13 Cruise control system (CCS)
  124
• 13.1 Cruise control system (CCS) for vehicles with electronic accelerator
  124
• 13.2 Cruise control system (CCS) for vehicles without electronic accelerator
  124
• 13.3 Adjusting control element
  126
• 13.4 Removing actuator
  126
• 13.5 Removing and installing breather valve
  126
• 13.6 Removing and installing cruise control system (CCS) vacuum pump V18
  127
• 13.7 Removing and installing cruise control system (CCS) control unit J213
  127
• 13.8 Checking vacuum system for leaks
  127
• Gauges, instruments
  128
• 1 Dash panel insert ► 12.95
  128
• 1.1 Removing and installing dash panel insert
  128
• 1.2 Assembly overview - dash panel insert with rev. counter or analogue clock
  129
• 1.3 Assembly overview - dash panel insert with multifunction indicator (MFI)
  131
• 1.4 Dismantling and assembling dash panel insert
  134
• 1.5 Pin assignment of connectors on dash panel insert
  143
• 2 Dash panel insert 01.96 ►07.98
  145
• 2.1 Removing and installing dash panel insert
  145
• 2.2 Pin assignment of connectors on dash panel insert
  147
• 3 Dash panel insert 08.98 ►
  149
• 3.1 Warning with oil level too low
  149
• 3.2 Fault detection and fault display
  149
• 3.3 Removing and installing dash panel insert
  150
• 3.4 Dash panel insert, rear view
  153
• 3.5 Pin assignment of connections on dash panel insert with no data BUS connection
  154
• 4 Service interval display
  159
• 4.1 Function
  159
• 4.3 Service interval display on dash panel inserts with data BUS connection
  161
• 5 Tachograph ► 04.99
  164
• 5.1 Pin assignment of the connections on the tachograph hood
  164
• 5.2 Pin assignment of connections on tachograph
  165
• 6 Tachograph 05.00 ►
  166
• 6.1 Pin assignment of connections on tachograph
  166
• 6.2 Removing and installing tachograph
  167
• Windscreen wash/wipe system
  169
• 1 Windscreen wiper system
  169
• 1.1 Assembly overview - windscreen wiper system
  169
• 1.2 Setting park position
  170
• 1.3 Adjusting wiper blade park position
  170
• 1.4 Removing and installing wiper rubber
  171
• 2 Window washer system (short front end) ► 12.95
  172
• 2.1 Assembly overview - windscreen washer system
  172
• 2.2 Removing and adjusting washer jets
  173
• 2.3 Hose connections at windscreen washer pump V5
  173
• 3 Window washer system (long front end) 01.96 ►
  174
• 3.1 Assembly overview - windscreen washer system
  174
• 3.2 Removing and adjusting washer jets
  175
• 3.3 Hose connections at windscreen washer pump V5
  175
• 4 Rear window wiper and washer system (tailgate)
  176
• 4.1 Assembly overview of rear window wipe/wash system
  176
• 4.2 Setting park position
  177
• 4.3 Adjusting rear window wiper park position
  177
• 4.4 Adjusting spray jet
  177
• 5 Rear window wiper and washer system (rear hinged doors)
  178
• 5.1 Assembly overview of rear window wipe/wash system
  178
• 5.2 Setting park position
  180
• 5.3 Adjusting rear window wiper park position
  180
• 5.4 Adjusting spray jet
  181
• 6 Headlight washer system
  182
• 6.1 Assembly overview - headlight washer system
  182
• 6.2 Removing and installing spray jet retainer
  182
• 6.3 Removing and installing spray jet pop-up cylinders
  183
• 6.4 Adjusting spray jets
  185
• 7 Hose repair
  186
• 7.1 General description
  186
• 7.2 Repairing smooth pipe
  186
• 7.3 Repairing corrugated pipe
  186
• Lights, bulbs, switches - exterior
  188
• 1 Headlights (short front end) ► 12.95
  188
• 1.1 Assembly overview - headlights
  188
• 1.2 Renewing headlight bulbs
  189
• 1.3 Removing and installing headlight insert
  189
• 1.5 Adjusting headlights
  191
• 2 Headlights (long front end) 01.96 ►
  192
• 2.1 Assembly overview - headlights
  192
• 2.2 Renewing headlight bulbs
  193
• 2.3 Removing and installing headlight insert
  193
• 2.5 Adjusting headlights
  195
• 3 Fog lights (short front end) ► 12.95
  196
• 3.1 Removing and installing fog lights
  196
• 3.2 Renewing fog light bulb
  196
• 3.3 Adjusting fog lights
  196
• 4 Fog lights (long front end) 01.96 ►
  198
• 4.1 Removing and installing fog lights
  198
• 4.2 Renewing fog light bulb
  198
• 4.3 Adjusting fog lights
  198
• 5 Turn signals and front (short front end) ► 12.95
  199
• 5.1 Removing and installing front turn signal
  199
• 5.2 Renewing front left turn signal bulb M5 and front right turn signal bulb M7
  199
• 6 Turn signals at front (long front end) 01.96 ►
  200
• 6.1 Removing and installing front turn signal
  200
• 6.2 Renewing front left turn signal bulb M5 and front right turn signal bulb M7
  200
• 7 Tail light cluster
  201
• 7.1 Removing and installing tail light cluster of a panel van
  201
• 7.2 Removing and installing drop-side tail light cluster
  202
• 8 Additional brake light
  203
• 8.1 Removing and installing high-level brake light bulb holder (rear lid)
  203
• 8.2 Removing and installing high-level brake light housing (rear lid)
  203
• 9 Number plate light
  204
• 9.1 Removing number plate lights
  204
• 10 Rear fog light
  205
• 10.1 Removing rear fog light
  205
• 11 Steering column switch and ignition/starter switch ►08.98
  206
• 11.1 Assembly overview - steering column
  206
• 11.2 Removing and installing steering column switch
  208
• 11.3 Pin assignment on steering column switch and ignition and starter switch
  209
• 11.5 Removing and installing steering lock housing
  210
• 11.6 Removing and installing lock cylinder
  212
• 12 Steering column switch and ignition/starter switch 08.98 ►
  214
• 12.1 Assembly overview - steering column
  214
• 12.2 Removing and installing steering column switch
  215
• 12.3 Removing and installing steering lock housing
  216
• 12.4 Removing and installing lock cylinder
  217
• 12.5 Pin assignment on steering column switch and ignition and starter switch
  217
• Lights, bulbs, switches - interior
  219
• 1 Immobiliser
  219
• 1.1 Assembly overview - immobiliser
  219
• 1.2 Immobiliser control unit J362
  219
• 1.3 Removing and installing immobiliser reader coil D2
  219
• 1.4 Transponder
  220
• 1.5 Fuel shut-off valve control unit J366
  220
• 2 Interior lights and switches
  229
• 2.1 Removing and installing light switch
  229
• 2.2 Removing and installing headlight range control regulator E102
  229
• 2.3 Removing and installing switches in centre of dash panel ► 12.95
  229
• 2.4 Removing and installing switches in centre of dash panel 01.96 ►
  230
• Wiring
  231
• 1 Relay plate
  231
• 1.1 Removing and installing relay plate
  231
• 1.2 Removing and installing multi-pin connector on back of relay plate
  232
• 2 Wiring harness and connector repairs
  234
• 2.1 Safety notes:
  234
• 2.2 General notes concerning repairs to vehicle electrical system
  234
• 2.3 Instructions concerning wiring harness and connector repairs
  234
• 2.4 Supplementary notes on repair of CAN bus wiring
  235
• 2.5 Wiring harness repair set VAS 1978
  235
• 3 Renewal of aerial wiring
  237
• 3.1 General description
  237
• 3.2 Assembly overview - aerial wire
  237
• 3.3 Installing a new aerial wire
  237