Electrical system

Chapter overview

• Starter, current supply, CCS
  1
• 1 Battery
  1
• 1.1 Battery concept in Touareg
  1
• 1.2 Types of battery
  2
• 1.3 Warning notices and safety regulations
  2
• 1.4 Battery terminal connection
  2
• 2 Checking battery
  3
• 3 Charging battery
  4
• 3.1 Charging battery with battery deactivation relay
  4
• 4 Disconnecting and reconnecting battery
  7
• 4.1 Disconnecting and reconnecting battery, vehicles with one-battery concept
  7
• 5 Removing and installing battery
  17
• 5.1 Removing and installing battery beneath front left seat
  17
• 6 Battery parallel circuit relay J581
  22
• 6.1 Removing and installing battery parallel circuit relay J581
  22
• 7 Battery master switch and isolator switch E74
  24
• 7.1 General description
  24
• 7.2 Assembly overview - battery master/isolator switch E74
  24
• 7.3 Detection of triggering
  24
• 7.4 Resetting after triggering
  25
• 7.5 Removing and installing battery master/isolator switch E74
  27
• 8 Specified torques: battery
  29
• 9 Slave start point, vehicles to 04/05
  30
• 9.1 Assembly overview - slave start point, vehicles to 04/05
  30
• 9.2 Removing and installing slave start point, vehicles to 04/05
  30
• 10 Slave start point, vehicles from 05/05
  34
• 10.1 Assembly overview - slave start point, vehicles from 05/05
  34
• 10.2 Removing and installing slave start point, vehicles from 05/05
  34
• 11 Starter
  37
• 11.1 Checking starter B
  37
• 11.2 Removing and installing starter, automatic gearbox
  38
• 11.3 Removing and installing starter, manual gearbox
  63
• 12 Specified torques: starter
  68
• 12.1 6-cylinder 3.2 l and 3.6 l FSI engine
  68
• 12.2 8-cyl. injection engine, direct injection (FSI)
  68
• 12.3 8-cylinder 4.2 l injection engine
  68
• 12.4 12-cylinder 6.0 l injection engine
  68
• 12.5 2.5 l, 5-cylinder TDI engine
  68
• 12.6 2.5 l, 5-cylinder TDI engine with diesel particulate filter
  69
• 12.7 3.0 l, 6-cylinder TDI engine
  69
• 12.8 4.9 l, 10-cylinder TDI engine
  69
• 13 Alternator
  70
• 13.1 Characteristics of alternators
  70
• 13.2 Checking poly V-belt
  71
• 13.3 Checking alternator C
  71
• 13.4 Alternator, air-cooled, 6-cylinder injection engine
  72
• 13.5 Alternator, water-cooled, 6-cylinder injection engine 3.2 l and 3.6 l FSI
  76
• 13.6 Alternator, 8-cyl. 4.2 l injection engine
  81
• 13.7 Alternator, 8-cyl. 4.2 l direct injection engine
  85
• 13.8 Alternator, 12-cyl. 6.0 l injection engine
  89
• 13.9 Alternator, 5-cyl. 2.5 l TDI engine
  92
• 13.10 Coolant-cooled alternator, 6-cyl. 3.0 l TDI engine
  98
• 13.11 Air-cooled alternator, 6-cyl. 3.0 l TDI engine
  105
• 13.12 Alternator, 10-cyl. 5.0 l TDI engine
  109
• 13.13 Removing and installing poly V-belt pulley on alternator
  123
• 13.14 Removing and installing poly V-belt pulley with freewheel on alternator
  126
• 13.15 Voltage regulator for alternator
  133
• 14 Cruise control system (CCS)
  136
• 14.1 General description
  136
• 14.2 Activating and deactivating cruise control system (CCS)
  136
• 15 Adaptive cruise control (ACC)
  137
• 15.1 General description
  137
• 15.2 Assembly overview
  137
• 15.3 Removing and installing adaptive cruise control button E357
  138
• 15.4 Removing and installing adaptive cruise control unit J428
  138
• 15.5 Calibrating adaptive cruise control sensor G550
  139
• 15.6 Initialising adaptive cruise control
  139
• 16 Distance monitoring system (Front Assist)
  141
• 16.1 General description
  141
• 16.2 Adaptive cruise control unit J428
  141
• 16.3 Adaptive cruise control button E357
  141
• Gauges, instruments
  142
• 1 Dash panel insert
  142
• 1.1 General description
  142
• 1.2 Renewing dash panel insert
  143
• 1.3 Removing and installing dash panel insert
  143
• 1.4 Dash panel insert final control diagnosis
  145
• 1.5 Description of back of dash panel insert
  146
• 1.6 Connection assignment for connector in dash panel insert, vehicles to 11/06
  147
• 1.9 Warning lamp symbols in dash panel insert, vehicles to 11/06
  149
• 1.10 Warning lamp symbols in dash panel insert, vehicles from 12/06 with monochrome display
  151
• 2 Service interval display
  154
• 2.1 Resetting service interval display
  154
• Windscreen wash/wipe system
  155
• 1 Windscreen wiper system
  155
• 1.1 General description
  155
• 1.2 Deactivating APP function of wiper motors from 11/07
  156
• 1.3 Assembly overview - windscreen wiper system
  157
• 1.4 Removing and installing windscreen wiper system
  158
• 1.5 Removing and installing wiper arms
  167
• 1.6 Adjusting wiper blade park position
  167
• 1.7 Removing and installing joint-free wiper
  168
• 1.8 Removing and installing rain sensor G213 / rain and light sensor G397
  170
• 1.9 Wiper motor control unit J400
  173
• 2 Windscreen washer system
  175
• 2.1 General description
  175
• 2.2 Assembly overview - windscreen washer system
  175
• 2.3 Removing and installing washer fluid reservoir
  177
• 2.4 Removing and installing windscreen and rear window washer pump V59
  179
• 2.5 Removing and installing windscreen washer fluid level sender G33
  179
• 2.6 Removing and installing windscreen washer system spray jets
  180
• 2.7 Adjusting windscreen washer system spray jets
  180
• 3 Rear window wiper system
  182
• 3.1 General description
  182
• 3.2 Assembly overview - rear window wiper system
  182
• 3.3 Removing and installing rear window wiper
  183
• 3.4 Adjusting rear window wiper park position
  186
• 3.5 Removing and installing joint-free wiper
  187
• 4 Rear window washer system
  189
• 4.1 General description
  189
• 4.2 Assembly overview - rear window washer system
  189
• 4.3 Renewing spray jet
  190
• 4.4 Adjusting spray jet
  190
• 5 Headlight washer system
  192
• 5.1 General description
  192
• 5.2 Assembly overview - headlight washer system
  192
• 5.3 Removing and installing headlight washer system pump V11
  193
• 5.4 Removing and installing spray jet pop-up cylinders
  194
• 5.5 Removing and installing spray jet assembly
  195
• 5.6 Adjusting headlight washer system spray jets
  196
• 5.7 Bleeding headlight washer system
  196
• 6 Washer fluid line hose couplings
  197
• 7 Hose repair
  198
• Lights, bulbs, switches - exterior
  199
• 1 Headlights with halogen bulbs up to 11/06
  199
• 1.1 General description
  199
• 1.2 Assembly overview - headlight
  199
• 1.3 Removing and installing headlight
  202
• 1.4 Removing and installing headlight mounting
  203
• 1.5 Adjusting headlight installation position
  211
• 1.6 Replacing headlight bulbs
  212
• 1.7 Removing and installing headlight range control motor
  218
• 1.8 Converting headlights for use when driving on the left or right
  219
• 1.9 Adjusting headlights
  221
• 2 Headlights with gas discharge bulbs up to 11/06
  222
• 2.1 General description
  222
• 2.2 Assembly overview - gas discharge headlights
  223
• 2.3 Removing and installing headlight
  226
• 2.4 Removing and installing headlight mounting
  227
• 2.5 Adjusting headlight installation position
  227
• 2.6 Renewing gas discharge bulbs in headlights
  227
• 2.7 Removing and installing headlight range control motor
  233
• 2.8 Headlight screen adjustment solenoid
  234
• 2.9 Headlight range control unit
  235
• 2.10 Vehicle level sender
  237
• 2.11 Converting headlights for use when driving on the left or right
  238
• 2.12 Adjusting headlights
  240
• 3 Headlights with gas discharge bulbs and cornering light to 11/06
  243
• 3.1 General description
  243
• 3.2 Assembly overview - headlight with gas discharge bulb and cornering light
  244
• 3.3 Removing and installing headlight
  249
• 3.4 Removing and installing headlight mounting
  250
• 3.5 Adjusting headlight installation position
  250
• 3.6 Replacing gas discharge bulbs and cornering light bulbs in headlights
  250
• 3.7 Headlight range control motor
  258
• 3.8 Dynamic cornering light control motor
  258
• 3.9 Swivel module position sensor
  258
• 3.10 Headlight screen adjustment solenoid
  258
• 3.11 Power output module for headlight
  259
• 3.12 Removing and installing gas discharge bulb control unit
  261
• 3.13 Cornering light and headlight range control unit J745
  262
• 3.14 Vehicle level sender
  267
• 3.15 Converting headlights for use when driving on the left or right
  268
• 3.16 Adjusting headlights
  272
• 3.17 Operation and safety notes for gas discharge bulbs
  272
• 4 Headlights with halogen bulbs from 12/06
  275
• 4.1 General description
  275
• 4.2 Assembly overview - headlights with halogen bulbs from 12/06
  275
• 4.3 Removing and installing headlight
  277
• 4.4 Removing and installing headlight mounting
  278
• 4.5 Adjusting headlight installation position
  279
• 4.6 Renewing bulbs in headlight with halogen bulbs from 12/06
  279
• 4.7 Headlight range control motor
  285
• 4.8 Converting headlights for use when driving on the left or right
  287
• 4.9 Adjusting headlights
  289
• 5 Headlights with gas discharge bulbs and cornering light from 12/06
  290
• 5.1 General description
  290
• 5.2 Assembly overview - headlight with gas discharge bulb and cornering light
  291
• 5.3 Removing and installing headlight
  295
• 5.4 Removing and installing headlight mounting
  297
• 5.5 Adjusting headlight installation position
  298
• 5.6 Replacing gas discharge bulbs and cornering light bulbs in headlights
  298
• 5.7 Headlight range control motor
  305
• 5.8 Dynamic cornering light control motor
  308
• 5.9 Swivel module position sensor
  308
• 5.10 Headlight screen adjustment solenoid
  309
• 5.11 Power output module for headlight
  309
• 5.12 Gas discharge bulb control unit
  311
• 5.13 Cornering light and headlight range control unit J745
  311
• 5.14 Vehicle level sender
  316
• 5.15 Converting headlights for use when driving on the left or right
  318
• 5.16 Adjusting headlights
  320
• 5.17 Operation and safety notes for gas discharge bulbs
  320
• 6 Fog lights
  323
• 6.1 Removing and installing fog light
  323
• 6.2 Removing and installing fog light bulb
  324
• 6.3 Checking fog lights
  325
• 6.4 Adjusting fog lights
  325
• 6.5 Fog light Touareg Volkswagen R GmbH
  325
• 7 mirror turn signal lamp and entry light in exterior mirror
  326
• 7.1 Turn signal repeater bulb
  326
• 7.2 Entry light in exterior mirror
  327
• 8 Tail lights (tail light cluster)
  329
• 8.1 Assembly overview - tail light (tail light cluster) in side panel
  329
• 8.2 Removing and installing tail light (tail light cluster) in side panel
  331
• 8.3 Removing and installing tail light (cluster) bulb carrier in side panel
  333
• 8.4 Adjustable tail light carrier in side panel
  334
• 8.5 Assembly overview - tail light (tail light cluster) in rear lid
  335
• 8.6 Removing and installing tail light (tail light cluster) in rear lid
  336
• 8.7 Removing and installing tail light (cluster) bulb carrier in rear lid
  337
• 8.8 Tail light (tail light cluster) gaps and shut lines
  338
• 9 Number plate light
  339
• 9.1 Removing and installing number plate left light X4 and number plate right light X5
  339
• 9.2 Checking number plate left light X4 and number plate right light X5
  339
• 10 Additional brake light bulb M25
  340
• 10.1 Removing and installing additional brake light M25
  340
• 10.2 Checking high-level brake light bulb M25
  341
• 11 Steering column switch
  342
• 11.1 Assembly overview - steering column switch
  342
• 11.2 Removing and installing steering column switch
  344
• 11.3 Dismantling and assembling steering column switch
  347
• 11.4 Pin assignment on steering column switch
  349
• 11.5 Steering column electronics control unit J527
  350
• 12 Rear window opening
  352
• 12.1 Emergency release of rear lid window
  352
• 12.2 Removing and installing button to open rear lid window E361
  352
• 12.3 Removing and installing rear lid window release unit V312
  354
• 13 Entry and start authorisation
  355
• 13.1 Emergency release of ignition key
  355
• 13.2 Entry and start authorisation switch E415
  356
• 13.3 Entry and start authorisation button E408
  358
• 13.4 Entry and start authorisation control unit J518
  359
• 13.5 Entry and start authorisation aerials and sensors
  362
• 14 Parking aid
  371
• 14.1 Assembly overview - parking aid
  371
• 14.2 Removing and installing parking aid control unit J446
  373
• 14.3 Removing and installing parking aid button E266
  375
• 14.4 Removing and installing front parking aid senders
  375
• 14.5 Removing and installing rear parking aid senders
  377
• 14.6 Removing and installing front left parking aid display Y13
  378
• 14.7 Removing and installing rear parking aid display Y15
  379
• 14.8 Removing and installing parking aid loudspeaker R169
  380
• 15 Side Assist (lane change assistant)
  382
• 15.1 General description
  382
• 15.2 Removing and installing lane change assist control unit with radar sensor
  382
• 15.3 Removing and installing lane change assist warning lamps in exterior mirror
  383
• 15.4 Calibrating lane change assistant (Side Assist)
  384
• 15.5 Lane change assist control unit final control diagnosis
  391
• 15.6 Coding lane change assist control unit
  391
• 16 Reversing camera system
  393
• 16.1 General description
  393
• 16.2 Removing and installing reversing camera
  394
• 16.3 Removing and installing reversing camera system control unit
  397
• 16.4 Calibrating reversing camera system
  399
• 17 Winch
  405
• 17.1 Winch with reel window
  405
• 17.2 Bumper carrier with winch mounting
  411
• 17.3 Winch E-box
  412
• 17.4 Additional relay carrier in E-box in plenum chamber
  416
• 17.5 Power relay
  418
• 17.6 Winch remote control
  419
• 18 Roof luggage basket with additional headlights
  422
• 18.1 Additional headlights on roof luggage basket
  422
• 18.2 Socket for additional headlights on roof luggage basket
  425
• 19 Specified torques: lights, bulbs, switches - exterior
  430
• 19.1 Specified torques: headlights
  430
• 19.2 Specified torques: fog lights
  430
• 19.3 Specified torques: tail light in side panel
  430
• 19.4 Specified torques: tail light in rear lid
  430
• 19.5 Torque settings: Steering column switch
  430
• 19.6 Torque settings: Rear window opening
  430
• 19.7 Torque settings: Winch
  430
• 19.8 Torque settings: Roof luggage basket with additional headlights
  431
• Lights, bulbs, switches - interior
  432
• 1 Interior lights and switches
  432
• 1.1 Tools
  432
• 1.4 Footwell lights
  434
• 1.5 Removing and installing illuminated sill panel moulding with lettering
  436
• 2 Lights and switches in engine compartment
  439
• 2.1 Removing and installing engine compartment light W27
  439
• 2.2 Removing and installing bonnet contact switch F266
  440
• 3 Lights and switches in dash panel
  441
• 3.1 Removing and installing light switch E1
  441
• 3.4 Removing and installing glove compartment light W6
  443
• 3.5 Removing and installing glove compartment light switch E26
  444
• 3.6 Removing and installing switches in centre of dash panel
  444
• 4 Lights and switches in front doors
  447
• 4.1 Removing and installing driver side switch module
  447
• 4.3 Removing and installing window regulator switch in front passenger door E107
  449
• 4.4 Remote release button for fuel filler flap and rear lid E463
  451
• 4.7 Front left entry light W31 and front right entry light W32
  456
• 4.9 Components - front door locks
  459
• 5 Lights and switches in rear doors
  461
• 5.3 Removing and installing ashtray illumination bulb L15
  461
• 5.5 Rear left entry light W33 and rear right entry light W34
  462
• 5.6 Rear left door warning lamp W37 and rear right door warning lamp W38
  463
• 5.7 Components - rear door locks
  463
• 6 Lights and switches in luggage compartment
  464
• 6.2 Luggage compartment light W3
  465
• 6.3 Rear lid light W51
  466
• 6.4 Rear lid lock unit F256
  467
• 6.5 Removing and installing AC/DC converter with socket, 12 V - 230 V U13
  468
• 7 Lights and switches in roof trim
  470
• 7.1 Removing and installing front interior light W1
  470
• 7.2 Removing and installing front passenger reading light W13 and driver side reading light W19
  470
• 7.3 Removing and installing button module for front interior/reading light
  471
• 7.4 Sunroof switch E8
  473
• 7.5 Removing and installing sliding sunroof switch illumination bulb L65
  474
• 7.7 Removing and installing roof display unit J702
  476
• 7.8 Removing and installing garage door operating unit E284
  476
• 8 Lights and switches in centre console
  478
• 8.1 Removing and installing centre armrest illumination L157
  478
• 8.2 Removing and installing storage compartment illumination switch F335
  479
• 8.3 Removing and installing exterior mirror adjustment module
  479
• 8.5 Removing and installing adaptive suspension operating unit E281
  480
• 8.6 Removing and installing module for running gear adjustment
  480
• 8.7 Operating panel for transfer box E473
  481
• 8.8 12 V socket
  481
• 8.9 Cigarette lighter U1
  481
• 9 Horn
  482
• 9.1 Removing and installing treble horn H2 and bass horn H7
  482
• 9.2 Checking treble horn H2 and bass horn H7
  482
• 10 Immobiliser, vehicles to 11/06
  483
• 10.1 General description
  483
• 10.2 Entry and start authorisation control unit J518
  484
• 10.3 Electronic steering column lock
  484
• 10.4 Engine control unit
  485
• 10.5 Exchanging all components
  486
• 10.6 Ignition key
  486
• 10.7 Online system test
  487
• 11 Immobiliser, vehicles from 12/06
  488
• 11.1 General description
  488
• 11.2 Immobiliser control unit J362
  489
• 11.3 Entry and start authorisation control unit J518
  489
• 11.4 Electronic steering column lock
  490
• 11.5 Engine control unit J623
  490
• 11.6 New immobiliser identity
  490
• 11.7 Ignition key
  492
• 11.8 Fazit system test
  493
• 12 Anti-theft alarm (ATA)
  494
• 12.1 Activating and deactivating anti-theft alarm
  494
• 12.2 Incorporation of trailer into vehicle anti-theft alarm system
  495
• 12.4 Removing and installing interior monitoring sensor G273
  496
• 12.5 Removing and installing vehicle inclination sender G384
  497
• 12.6 Central locking and anti-theft alarm system aerial R47
  498
• 12.7 Alarm horn H12 (back-up horn)
  502
• 13 Specified torques: lights, bulbs and switches - interior
  504
• 13.1 Torque settings: alarm horn H12
  504
• Wiring
  505
• 1 Vehicle diagnosis, testing and information systems
  505
• 2 Fuse holder
  506
• 2.1 Removing and installing fuse holder
  506
• 2.2 Removing and installing pre-fuse box
  507
• 3 Relay carriers
  508
• 3.1 Removing and installing relay carrier in front left footwell
  508
• 4 Electronics boxes
  510
• 4.1 Removing and installing E-box in plenum chamber on left
  510
• 5 Control units
  512
• 5.1 Onboard supply control unit J519
  513
• 5.2 Data bus diagnostic interface J533
  517
• 5.3 Convenience system central control unit J393
  518
• 5.4 Entry and start authorisation control unit J518
  522
• 5.5 Trailer detector control unit J345
  524
• 5.6 Garage door operation control unit J530
  527
• 6 Wiring harness and connector repairs
  528