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Electrical system

For Polo

Original Volkswagen repair manual


26,30 €7% VAT incl.

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  • English

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Language: English

Digital PDF file

6.404 KB

339 Sites

Detailed technical data

Immediately readable

This repair manual contains: Battery, Disconnecting and reconnecting batteries, Specified torques: starter, Alternator, vehicles up to 03.05, Cruise control system (CCS), Dash panel insert, Headlight washer system, Washer fluid line hose couplings, Hose repair, Additional brake light, Steering column switch, Ignition/starter switch and lock cylinder, Lights and switches in luggage compartment, Immobilizer and Potential distributor. Show more
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Repair manual Polo 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 reconnecting batteries
    4
  • 4.1 Disconnecting battery
    4
  • 4.2 Connecting battery
    5
  • 5 Removing and installing battery
    8
  • 5.1 Removing battery
    8
  • 5.2 Installing battery
    8
  • 5.3 Removing and installing battery console (vehicles as of 04.05)
    9
  • 6 Specified torques: battery
    13
  • 7 Starter
    14
  • 7.1 Checking starter B
    14
  • 7.2 Removing and installing starter, manual gearbox
    14
  • 7.3 Removing and installing starter, automatic gearbox
    28
  • 8 Specified torques: starter
    32
  • 9 Alternator, vehicles up to 03.05
    33
  • 9.1 Securing battery positive wire to alternator
    33
  • 9.2 Checking poly V-belt
    33
  • 9.3 Checking alternator C
    33
  • 9.4 Alternator, 1.2 l 40 kW or 47 kW injection engine
    34
  • 9.5 Alternator, 1.4 l 55 kW or 74 kW injection engine
    37
  • 9.6 Alternator, 1.4 l 63 kW FSI engine
    42
  • 9.7 Alternator, 1.6 l 77 kW injection engine
    45
  • 9.8 Alternator, 1.4 l 51 kW or 55 kW TDI engine
    49
  • 9.9 Alternator, 1.9 l 47 kW SDI engine
    52
  • 9.10 Alternator, 1.9 l 74 kW or 96 kW TDI engine
    56
  • 9.11 Removing and installing poly V-belt pulley on alternator
    60
  • 9.12 Voltage regulator for alternator
    64
  • 10 Alternator, vehicles as of 04.05
    68
  • 10.1 Securing battery positive wire to alternator
    68
  • 10.2 Checking poly V-belt
    68
  • 10.3 Checking alternator C
    68
  • 10.4 Alternator, 1.2 l 40 kW or 47 kW injection engine
    68
  • 10.5 Alternator, 1.4 l 55 kW or 74 kW injection engine
    68
  • 10.6 Alternator, 1.4 l 63 kW FSI engine
    68
  • 10.7 Alternator, 1.6 l 77 kW injection engine
    68
  • 10.8 Alternator, 1.8 l 110 kW turbo engine
    72
  • 10.9 Alternator, 1.4 l 51 kW, 55 kW or 59 kW TDI engine
    77
  • 10.10 Alternator, 1.9 l 47 kW SDI engine
    80
  • 10.11 Alternator, 1.9 l 74 kW or 96 kW TDI engine
    80
  • 10.12 Removing and installing poly V-belt pulley on alternator
    85
  • 10.13 Voltage regulator for alternator
    85
  • 11 Alternator, vehicles as of 06.06
    86
  • 11.1 Securing battery positive wire to alternator
    86
  • 11.2 Checking poly V-belt
    86
  • 11.3 Checking alternator C
    86
  • 11.4 Alternator, 1.2 l 40 kW or 47 kW injection engine
    86
  • 11.5 Alternator, 1.4 l 55 kW or 74 kW injection engine
    86
  • 11.6 Alternator, 1.4 l 59 kW injection engine with air conditioning system
    86
  • 11.7 Alternator, 1.4 l 59 kW injection engine with air no conditioning system
    90
  • 11.8 Alternator, 1.6 l 77 kW injection engine
    94
  • 11.9 Alternator, 1.8 l 110 kW turbo engine
    94
  • 11.10 Alternator, 1.4 l 51 kW or 59 kW TDI engine
    94
  • 11.11 Alternator, 1.9 l 74 kW or 96 kW TDI engine
    94
  • 11.12 Removing and installing poly V-belt pulley on alternator
    94
  • 11.13 Voltage regulator for alternator
    94
  • 12 Alternator, vehicles with diesel particulate filter
    96
  • 12.1 Securing battery positive wire to alternator
    96
  • 12.2 Checking poly V-belt
    96
  • 12.3 Checking alternator C
    96
  • 12.4 Alternator, 1.4 l 51 kW TDI engine with air conditioning system
    96
  • 12.5 Alternator, 1.4 l 51 kW TDI engine with no air conditioning system
    100
  • 12.6 Alternator, 1.4 l 59 kW TDI engine with air conditioning system
    104
  • 12.7 Alternator, 1.4 l 59 kW TDI engine with no air conditioning system
    109
  • 12.8 Alternator, 1.9 l 74 kW TDI engine with air conditioning system
    112
  • 12.9 Alternator, 1.9 l 74 kW TDI engine with no air conditioning system
    117
  • 12.10 Removing and installing poly V-belt pulley on alternator
    121
  • 12.11 Voltage regulator for alternator
    121
  • 13 Cruise control system (CCS)
    122
  • 13.1 Activating and deactivating cruise control system (CCS)
    122
  • Gauges, instruments
    123
  • 1 Dash panel insert
    123
  • 1.1 Renewing dash panel insert
    123
  • 1.2 Removing and installing dash panel insert
    124
  • 1.3 Description of back of dash panel insert
    125
  • 1.4 Warning lamp symbols in dash panel insert
    125
  • 2 Service interval display
    127
  • 2.1 Resetting service interval display
    127
  • Windscreen wash/wipe system
    128
  • 1 Windscreen wiper system
    128
  • 1.1 Removing and installing windscreen wiper system
    128
  • 1.2 Adjusting wiper blade park position
    133
  • 1.3 Aerodynamic wiper
    136
  • 1.4 Removing and installing rain sensor G213
    137
  • 1.5 Fitting a new adhesive pad to the rain sensor (Valeo)
    138
  • 2 Windscreen washer system
    143
  • 2.1 Assembly overview - windscreen washer system
    143
  • 2.2 Removing and installing reservoir for windscreen and headlight washer system
    145
  • 2.3 Removing and installing windscreen and rear window washer pump V59
    146
  • 2.4 Removing and installing windscreen washer fluid level sender G33
    147
  • 2.5 Removing and installing windscreen washer jets
    148
  • 2.6 Cleaning spray jets for front windscreen washer system
    148
  • 2.7 Adjusting windscreen washer system washer jets
    148
  • 3 Rear window wiper system
    149
  • 3.1 Assembly overview - rear window wiper system
    149
  • 3.2 Removing and installing rear window wiper
    149
  • 3.3 Adjusting rear window wiper park position
    150
  • 4 Rear window washer system
    152
  • 4.1 Assembly overview - rear window washer system
    152
  • 4.2 Removing and installing spray jet
    153
  • 4.3 Cleaning spray jet
    153
  • 4.4 Adjusting washer jet
    153
  • 5 Headlight washer system
    154
  • 5.1 Assembly overview - headlight washer system
    154
  • 5.2 Removing and installing washer jet assembly
    156
  • 5.3 Removing and installing pop-up washer spray jet cylinder, vehicles up to 03.05
    156
  • 5.4 Removing and installing pop-up washer spray jet cylinder, vehicles as of 04.05
    157
  • 5.5 Removing and installing headlight washer system pump V11
    158
  • 5.6 Adjusting headlight washer system jets
    158
  • 5.7 Bleeding headlight washer system
    158
  • 6 Washer fluid line hose couplings
    159
  • 7 Hose repair
    160
  • 8 Specified torques for windscreen wash/wipe system
    161
  • Lights, bulbs, switches - exterior
    162
  • 1 Headlight, vehicles up to 03.05
    162
  • 1.1 Assembly overview - headlight
    162
  • 1.2 Removing and installing headlight
    163
  • 1.3 Adjusting headlight installation position
    165
  • 1.4 Renewing headlight bulbs
    166
  • 1.5 Headlight range control motor
    174
  • 1.6 Repairing headlight retaining tabs
    179
  • 1.7 Converting headlights for use when driving on the left or right
    181
  • 1.8 Adjusting headlight
    183
  • 2 Headlight, vehicles as of 04.05
    184
  • 2.1 Assembly overview - headlight
    184
  • 2.2 Removing and installing headlight
    186
  • 2.3 Adjusting headlight installation position
    187
  • 2.4 Renewing headlight bulbs; headlight manufacturer: Hella
    189
  • 2.5 Renewing headlight bulbs; headlight manufacturer: Valeo
    198
  • 2.6 Headlight range control motor
    206
  • 2.7 Repairing headlight retaining tabs
    212
  • 2.8 Converting headlights for use when driving on the left or right
    215
  • 2.9 Adjusting headlight
    217
  • 3 Front fog light, vehicles up to 03.05
    218
  • 3.1 Fog lights (except Polo Fun)
    218
  • 3.2 Fog lights (Polo Fun only)
    220
  • 3.3 Adjusting fog light
    222
  • 4 Front fog light, vehicles as of 04.05
    223
  • 4.1 Fog lights (except Polo Cross/Dune)
    223
  • 4.2 Fog light Polo Cross (Polo Dune)
    225
  • 4.3 Adjusting fog light
    226
  • 5 Side mounted repeater turn signals, vehicles up to 03.05
    227
  • 5.1 Removing and installing side mounted repeater turn signal
    227
  • 6 Mirror turn signal bulb in exterior mirror, vehicles from 04.05
    228
  • 7 Tail lights, vehicles up to 03.05
    229
  • 7.1 Assembly overview - tail lights
    229
  • 7.2 Removing and installing tail light
    230
  • 7.3 Removing and installing bulb holder
    231
  • 8 Tail lights, vehicles as of 04.05
    232
  • 8.1 Assembly overview - tail lights
    232
  • 8.2 Removing and installing tail light
    232
  • 8.3 Removing and installing bulb holder
    233
  • 9 Additional brake light
    235
  • 9.1 Additional brake light (except Polo GTI, Polo Blue Motion)
    235
  • 9.2 Additional brake light (Polo GTI, Polo Blue Motion)
    236
  • 10 Number plate lights
    238
  • 10.1 Removing and installing number plate light X
    238
  • 11 Steering column switch
    239
  • 11.1 Removing and installing steering column switch
    240
  • 11.3 Basic setting of steering angle sensor G85
    243
  • 12 Ignition/starter switch and lock cylinder
    245
  • 12.1 Removing and installing lock cylinder
    245
  • 12.2 Ignition/starter switch D
    246
  • 13 Steering lock housing
    248
  • 13.1 Removing and installing steering lock housing
    248
  • 14 Parking aid, vehicles as of 04.05
    250
  • 14.1 Assembly overview
    250
  • 14.2 Parking aid control unit J446
    251
  • 14.3 Parking aid warning buzzer H15
    253
  • 14.4 Rear parking aid senders
    253
  • 15 Specified torques: lights, bulbs, switches - exterior
    256
  • 15.1 Specified torques: headlight
    256
  • 15.2 Specified torques: fog light
    256
  • 15.3 Specified torques: tail light
    256
  • 15.4 Specified torques: additional brake light
    256
  • 15.5 Specified torques: steering column switch
    256
  • Lights, bulbs, switches - interior
    257
  • 1 Interior lights and switches
    257
  • 1.1 Removing and installing interior monitoring deactivation switch E267
    257
  • 2 Lights and switches in engine compartment
    258
  • 2.1 Removing and installing bonnet contact switch F266
    258
  • 3 Lights and switches in dash panel
    259
  • 3.1 Removing and installing light switch E1
    259
  • 3.3 Removing and installing switches, lights and regulators in centre of dash panel
    260
  • 4 Lights and switches in front doors
    263
  • 4.1 Removing and installing switch module for driver side window lift
    263
  • 4.2 Removing and installing window lift switch in passenger door E107
    263
  • 4.3 Removing and installing switch module for driver side mirror adjustment
    264
  • 4.4 Removing and installing driver side interior locking switch E150
    264
  • 4.7 Removing and installing door contact switch
    267
  • 5 Lights and switches in rear doors
    269
  • 5.1 Removing and installing rear left window regulator switch in door E52
    269
  • 5.2 Removing and installing rear right window regulator switch in door E54
    269
  • 6 Lights and switches in luggage compartment
    270
  • 6.1 Removing and installing luggage compartment light switch F5
    270
  • 6.2 Removing and installing luggage compartment light W3
    270
  • 7 Lights and switches in roof trim
    272
  • 7.1 Front interior light W1
    272
  • 7.2 Front interior light W1 with reading lights and preparation for telephone
    274
  • 7.3 Front interior light W1 with reading lights and regulator for sunroof
    278
  • 7.4 Rear interior light W43
    282
  • 7.5 Removing and installing illuminated vanity mirror
    283
  • 8 Horn
    286
  • 8.1 Single tone horn
    286
  • 8.2 Dual tone horn
    287
  • 8.3 Horn plate H
    289
  • 9 Immobilizer
    291
  • 9.1 Immobilizer control unit J362
    291
  • 9.2 Immobilizer reader coil D2
    291
  • 9.3 Ignition key
    291
  • 10 Anti-theft alarm system (ATA)
    293
  • 10.1 Activating and deactivating anti-theft alarm system
    293
  • 10.2 Removing and installing interior monitoring deactivation switch E267
    294
  • 10.3 Anti-theft alarm ultrasonic sensor G209
    294
  • 10.4 Central locking and anti-theft alarm system aerial R47
    296
  • 10.5 Alarm horn H12
    297
  • 11 Specified torques: lights, bulbs, switches - interior
    298
  • 11.1 Specified torques: horn or dual tone horn H1
    298
  • 11.2 Specified torques: signal horn activation H
    298
  • 11.3 Specified torques: alarm horn H12
    298
  • Wiring
    299
  • 1 Vehicle diagnosis, testing and information systems
    299
  • 2 Fuse holder
    300
  • 2.1 Removing and installing fuse holder
    300
  • 2.2 Main fuse carrier, vehicles up to 03.05
    300
  • 2.3 Main fuse carrier, vehicles as of 04.05
    305
  • 3 Relay carrier
    313
  • 3.1 Removing and installing relay carrier
    313
  • 4 Potential distributor
    315
  • 4.1 Removing and installing voltage distributor
    315
  • 5 Connector points and compact connector
    316
  • 5.1 A-pillar coupling station
    316
  • 5.2 B-pillar coupling station
    316
  • 5.3 Compact connector at bulkhead
    316
  • 6 Repairing connector on steering column switch
    320
  • 6.1 Checking and renewing housing and contacts of 41-pin connector T41
    320
  • 7 Control units
    324
  • 7.1 Onboard supply control unit J519
    324
  • 7.2 Data bus diagnostic interface J533
    328
  • 7.3 Convenience system central control unit J393
    328
  • 8 Specified torques: wires/cables
    330
  • 8.1 Specified torques: fuse holder
    330
  • 8.2 Specified torques: main fuse carrier
    330
  • 8.3 Specified torques: compact connector
    330
  • 9 Wiring harness and connector repairs
    331
Manufacturer's designation Electrical system
Manufacturer Volkswagen
Suitable for Polo (2002 - 2005) / Polo (2005 - 2007)
Suitable car types 9N1, 9N3
Category Reparaturanleitung

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