Electrical system South Africa

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
  38
• 9.6 Alternator, 1.4 l 63 kW FSI engine
  44
• 9.7 Alternator, 1.6 l 77 kW injection engine
  49
• 9.8 Alternator, 1.4 l 51 kW or 55 kW TDI engine
  54
• 9.9 Alternator, 1.9 l 47 kW SDI engine
  59
• 9.10 Alternator, 1.9 l 74 kW or 96 kW TDI engine
  63
• 9.11 Removing and installing poly V-belt pulley on alternator
  68
• 9.12 Voltage regulator for alternator
  72
• 10 Alternator, vehicles as of 04.05
  76
• 10.1 Securing battery positive wire to alternator
  76
• 10.2 Checking poly V-belt
  76
• 10.3 Checking alternator C
  76
• 10.4 Alternator, 1.2 l 40 kW or 47 kW injection engine
  76
• 10.5 Alternator, 1.4 l 55 kW or 74 kW injection engine
  76
• 10.6 Alternator, 1.4 l 63 kW FSI engine
  76
• 10.7 Alternator, 1.6 l 77 kW injection engine
  76
• 10.8 Alternator, 1.8 l 110 kW turbo engine
  81
• 10.9 Alternator, 1.4 l 51 kW, 55 kW or 59 kW TDI engine
  87
• 10.10 Alternator, 1.9 l 47 kW SDI engine
  92
• 10.11 Alternator, 1.9 l 74 kW or 96 kW TDI engine
  92
• 10.12 Removing and installing poly V-belt pulley on alternator
  98
• 10.13 Voltage regulator for alternator
  98
• 11 Alternator, vehicles as of 06.06
  99
• 11.1 Securing battery positive wire to alternator
  99
• 11.2 Checking poly V-belt
  99
• 11.3 Checking alternator C
  99
• 11.4 Alternator, 1.2 l 40 kW or 47 kW injection engine
  99
• 11.5 Alternator, 1.4 l 55 kW or 74 kW injection engine
  99
• 11.6 Alternator, 1.4 l 59 kW injection engine with air conditioning system
  99
• 11.7 Alternator, 1.4 l 59 kW injection engine with air no conditioning system
  104
• 11.8 Alternator, 1.6 l 77 kW injection engine
  109
• 11.9 Alternator, 1.8 l 110 kW turbo engine
  109
• 11.10 Alternator, 1.4 l 51 kW or 59 kW TDI engine
  109
• 11.11 Alternator, 1.9 l 74 kW or 96 kW TDI engine
  109
• 11.12 Removing and installing poly V-belt pulley on alternator
  109
• 11.13 Voltage regulator for alternator
  109
• 12 Alternator, vehicles with diesel particulate filter
  111
• 12.1 Securing battery positive wire to alternator
  111
• 12.2 Checking poly V-belt
  111
• 12.3 Checking alternator C
  111
• 12.4 Alternator, 1.4 l 51 kW TDI engine with air conditioning system
  111
• 12.5 Alternator, 1.4 l 51 kW TDI engine with no air conditioning system
  116
• 12.6 Alternator, 1.4 l 59 kW TDI engine with air conditioning system
  122
• 12.7 Alternator, 1.4 l 59 kW TDI engine with no air conditioning system
  127
• 12.8 Alternator, 1.9 l 74 kW TDI engine with air conditioning system
  132
• 12.9 Alternator, 1.9 l 74 kW TDI engine with no air conditioning system
  137
• 12.10 Removing and installing poly V-belt pulley on alternator
  143
• 12.11 Voltage regulator for alternator
  143
• 13 Cruise control system (CCS)
  144
• 13.1 Activating and deactivating cruise control system (CCS)
  144
• Gauges, instruments
  145
• 1 Dash panel insert
  145
• 1.1 Renewing dash panel insert
  145
• 1.2 Removing and installing dash panel insert
  146
• 1.3 Description of back of dash panel insert
  147
• 1.4 Warning lamp symbols in dash panel insert
  147
• 2 Service interval display
  149
• 2.1 Resetting service interval display
  149
• Windscreen wash/wipe system
  150
• 1 Windscreen wiper system
  150
• 1.1 Removing and installing windscreen wiper system
  150
• 1.2 Adjusting wiper blade park position
  155
• 1.3 Aerodynamic wiper
  158
• 1.4 Removing and installing rain sensor G213
  159
• 1.5 Fitting a new adhesive pad to the rain sensor (Valeo)
  160
• 2 Windscreen washer system
  165
• 2.1 Assembly overview - windscreen washer system
  165
• 2.2 Removing and installing reservoir for windscreen and headlight washer system
  167
• 2.3 Removing and installing windscreen and rear window washer pump V59
  168
• 2.4 Removing and installing windscreen washer fluid level sender G33
  169
• 2.5 Removing and installing windscreen washer jets
  170
• 2.6 Cleaning spray jets for front windscreen washer system
  170
• 2.7 Adjusting windscreen washer system washer jets
  170
• 3 Rear window wiper system
  171
• 3.1 Assembly overview - rear window wiper system
  171
• 3.2 Removing and installing rear window wiper
  171
• 3.3 Adjusting rear window wiper park position
  172
• 4 Rear window washer system
  174
• 4.1 Assembly overview - rear window washer system
  174
• 4.2 Removing and installing spray jet
  175
• 4.3 Cleaning spray jet
  175
• 4.4 Adjusting washer jet
  175
• 5 Headlight washer system
  176
• 5.1 Assembly overview - headlight washer system
  176
• 5.2 Removing and installing washer jet assembly
  178
• 5.3 Removing and installing pop-up washer spray jet cylinder, vehicles up to 03.05
  178
• 5.4 Removing and installing pop-up washer spray jet cylinder, vehicles as of 04.05
  179
• 5.5 Removing and installing headlight washer system pump V11
  180
• 5.6 Adjusting headlight washer system jets
  180
• 5.7 Bleeding headlight washer system
  180
• 6 Washer fluid line hose couplings
  181
• 7 Hose repair
  182
• 8 Specified torques for windscreen wash/wipe system
  183
• Lights, bulbs, switches - exterior
  184
• 1 Headlight, vehicles up to 03.05
  184
• 1.1 Assembly overview - headlight
  184
• 1.2 Removing and installing headlight
  185
• 1.3 Adjusting headlight installation position
  187
• 1.4 Renewing headlight bulbs
  188
• 1.5 Headlight range control motor
  196
• 1.6 Repairing headlight retaining tabs
  201
• 1.7 Converting headlights for use when driving on the left or right
  203
• 1.8 Adjusting headlight
  205
• 2 Headlight, vehicles as of 04.05
  206
• 2.1 Assembly overview - headlight
  206
• 2.2 Removing and installing headlight
  208
• 2.3 Adjusting headlight installation position
  209
• 2.4 Renewing headlight bulbs; headlight manufacturer: Hella
  211
• 2.5 Renewing headlight bulbs; headlight manufacturer: Valeo
  220
• 2.6 Headlight range control motor
  228
• 2.7 Repairing headlight retaining tabs
  234
• 2.8 Converting headlights for use when driving on the left or right
  237
• 2.9 Adjusting headlight
  239
• 3 Front fog light, vehicles up to 03.05
  240
• 3.1 Fog lights (except Polo Fun)
  240
• 3.2 Fog lights (Polo Fun only)
  242
• 3.3 Adjusting fog light
  244
• 4 Front fog light, vehicles as of 04.05
  245
• 4.1 Fog lights (except Polo Cross/Dune)
  245
• 4.2 Fog light Polo Cross (Polo Dune)
  247
• 4.3 Adjusting fog light
  248
• 5 Side mounted repeater turn signals, vehicles up to 03.05
  249
• 5.1 Removing and installing side mounted repeater turn signal
  249
• 6 Mirror turn signal bulb in exterior mirror, vehicles from 04.05
  250
• 7 Tail lights, vehicles up to 03.05
  251
• 7.1 Assembly overview - tail lights
  251
• 7.2 Removing and installing tail light
  252
• 7.3 Removing and installing bulb holder
  253
• 8 Tail lights, vehicles as of 04.05
  254
• 8.1 Assembly overview - tail lights
  254
• 8.2 Removing and installing tail light
  254
• 8.3 Removing and installing bulb holder
  255
• 9 Additional brake light
  257
• 9.1 Additional brake light (except Polo GTI, Polo Blue Motion)
  257
• 9.2 Additional brake light (Polo GTI, Polo Blue Motion)
  258
• 10 Number plate lights
  260
• 10.1 Removing and installing number plate light X
  260
• 11 Steering column switch
  261
• 11.1 Removing and installing steering column switch
  262
• 11.3 Basic setting of steering angle sensor G85
  265
• 12 Ignition/starter switch and lock cylinder
  267
• 12.1 Removing and installing lock cylinder
  267
• 12.2 Ignition/starter switch D
  268
• 13 Steering lock housing
  270
• 13.1 Removing and installing steering lock housing
  270
• 14 Parking aid, vehicles as of 04.05
  272
• 14.1 Assembly overview
  272
• 14.2 Parking aid control unit J446
  273
• 14.3 Parking aid warning buzzer H15
  275
• 14.4 Rear parking aid senders
  275
• 15 Specified torques: lights, bulbs, switches - exterior
  278
• 15.1 Specified torques: headlight
  278
• 15.2 Specified torques: fog light
  278
• 15.3 Specified torques: tail light
  278
• 15.4 Specified torques: additional brake light
  278
• 15.5 Specified torques: steering column switch
  278
• Lights, bulbs, switches - interior
  279
• 1 Interior lights and switches
  279
• 1.1 Removing and installing interior monitoring deactivation switch E267
  279
• 2 Lights and switches in engine compartment
  280
• 2.1 Removing and installing bonnet contact switch F266
  280
• 3 Lights and switches in dash panel
  281
• 3.1 Removing and installing light switch E1
  281
• 3.3 Removing and installing switches, lights and regulators in centre of dash panel
  282
• 4 Lights and switches in front doors
  285
• 4.1 Removing and installing switch module for driver side window lift
  285
• 4.2 Removing and installing window lift switch in passenger door E107
  285
• 4.3 Removing and installing switch module for driver side mirror adjustment
  286
• 4.4 Removing and installing driver side interior locking switch E150
  286
• 4.7 Removing and installing door contact switch
  289
• 5 Lights and switches in rear doors
  291
• 5.1 Removing and installing rear left window regulator switch in door E52
  291
• 5.2 Removing and installing rear right window regulator switch in door E54
  291
• 6 Lights and switches in luggage compartment
  292
• 6.1 Removing and installing luggage compartment light switch F5
  292
• 6.2 Removing and installing luggage compartment light W3
  292
• 7 Lights and switches in roof trim
  294
• 7.1 Front interior light W1
  294
• 7.2 Front interior light W1 with reading lights and preparation for telephone
  296
• 7.3 Front interior light W1 with reading lights and regulator for sunroof
  300
• 7.4 Rear interior light W43
  304
• 7.5 Removing and installing illuminated vanity mirror
  305
• 8 Horn
  308
• 8.1 Single tone horn
  308
• 8.2 Dual tone horn
  309
• 8.3 Horn plate H
  311
• 9 Immobilizer
  313
• 9.1 Immobilizer control unit J362
  313
• 9.2 Immobilizer reader coil D2
  313
• 9.3 Ignition key
  313
• 10 Anti-theft alarm system (ATA)
  315
• 10.1 Activating and deactivating anti-theft alarm system
  315
• 10.2 Removing and installing interior monitoring deactivation switch E267
  316
• 10.3 Anti-theft alarm ultrasonic sensor G209
  316
• 10.4 Central locking and anti-theft alarm system aerial R47
  318
• 10.5 Alarm horn H12
  319
• 11 Specified torques: lights, bulbs, switches - interior
  322
• 11.1 Specified torques: horn or dual tone horn H1
  322
• 11.2 Specified torques: signal horn activation H
  322
• 11.3 Specified torques: alarm horn H12
  322
• Wiring
  323
• 1 Vehicle diagnosis, testing and information systems
  323
• 2 Fuse holder
  324
• 2.1 Removing and installing fuse holder
  324
• 2.2 Main fuse carrier, vehicles up to 03.05
  324
• 2.3 Main fuse carrier, vehicles as of 04.05
  329
• 3 Relay carrier
  337
• 3.1 Removing and installing relay carrier
  337
• 4 Potential distributor
  339
• 4.1 Removing and installing voltage distributor
  339
• 5 Connector points and compact connector
  340
• 5.1 A-pillar coupling station
  340
• 5.2 B-pillar coupling station
  340
• 5.3 Compact connector at bulkhead
  340
• 6 Control units
  344
• 6.1 Onboard supply control unit J519
  344
• 6.2 Data bus diagnostic interface J533
  348
• 6.3 Convenience system central control unit J393
  348
• 7 Specified torques: wires/cables
  350
• 7.1 Specified torques: fuse holder
  350
• 7.2 Specified torques: main fuse carrier
  350
• 7.3 Specified torques: compact connector
  350
• 8 Wiring harness and connector repairs
  351