Electrical system from August 1998

Chapter overview

• Starter, Current supply
  1
• 1 Battery
  1
• 1.1 Battery
  1
• 1.2 Fundamentals for batteries
  1
• 1.3 Battery handling instructions
  1
• 1.4 Visual check
  2
• 1.5 Battery discharge (load) test
  2
• 1.6 Battery charging
  4
• 1.7 Removing and installing battery
  5
• 2 Batteries with condition indicator and sealed cell plugs
  10
• 2.1 Batteries with condition indicator and sealed cell plugs
  10
• 2.2 Checking battery via the condition indicator
  10
• 2.3 Checking and correcting electrolyte level
  11
• 3 Batteriens with condition indicator and without cell plugs
  14
• 3.1 Batteriens with condition indicator and without cell plugs
  14
• 3.2 Checking battery via condition indicator
  15
• 4 Batteries without condition indicator
  15
• 4.1 Batteries without condition indicator
  15
• 4.2 Checking and correcting electrolyte level
  16
• 5 Starter
  19
• 5.1 Starter
  19
• 5.2 Removing and installing starter
  19
• 6 Removing and installing alternator
  22
• 6.1 Removing and installing alternator
  22
• 6.2 Alternator with ribbed belt
  23
• 6.3 4-cylinder engine with 90A alternator > 04.99
  24
• 6.4 4-cylinder engine with 90A alternator 05.99 >
  25
• 6.5 4-cylinder engine with 120A alternator > 04.99
  27
• 6.6 4-cylinder engine with 120A alternator 05.99 >
  29
• 6.7 4-cylinder engine with air conditioning compressor or auxiliary alternator > 04.99
  32
• 6.8 4-cylinder engine with air conditioning compressor or auxiliary alternator 05.99 >
  34
• 6.9 5-cylinder engine without air conditioning compressor or auxiliary alternator > 04.99
  37
• 6.10 5-cylinder engine without air conditioning compressor or auxiliary alternator 05.99 >
  39
• 05.99 >
  43
• 6.13 6-cylinder injection engine > 04.99
  46
• 6.14 6-cylinder injection engine 05.99 >
  49
• 6.15 Removing and installing ribbed V-belt, 4 cylinder diesel engine
  56
• 6.16 Removing and installing ribbed V-belt, 4 cylinder petrol engine
  59
• 6.17 Removing and installing ribbed belt, 5-cylinder engine
  61
• 6.18 Removing and installing ribbed belt, 6-cylinder engine
  62
• 6.19 Compact alternator with ribbed belt drive >04.99
  63
• 6.20 Checking alternator carbon brushes > 04.99
  64
• 6.21 Removing and installing voltage regulator for alternator > 04.99
  65
• 6.22 Compact alternator with ribbed belt drive 05.99 >
  65
• 6.23 Checking alternator carbon brushes 05.99 >
  66
• 6.24 Removing and installing voltage regulator for alternator 05.99 >
  66
• 6.25 Replacing alternator ribbed belt pulley
  67
• 6.26 Removing and installing ribbed belt pulley with freewheel
  68
• 7 Cruise control system (CCS)
  69
• 7.1 Cruise control system (CCS)
  69
• 7.2 Cruise control system (CCS) for vehicles with electronic power control
  69
• 7.3 Cruise control system (CCS) for vehicles without electronic power control
  70
• 7.4 Adjusting positioning element
  74
• 7.5 Removing positioning element
  74
• 7.6 Removing and installing vent valve
  75
• 7.7 Removing and installing CCS vacuum pump (V18)
  75
• 7.8 Removing and installing CCS control unit (J213)
  76
• 7.9 Checking the vacuum system for leaks
  76
• Gauges, Instruments
  77
• 1 Dash panel insert
  77
• 1.1 Dash panel insert
  77
• 1.2 Removing and installing dash panel insert
  78
• 1.3 Dash panel insert, rear
  81
• 1.4 Connector contact assignment on dash panel insert without data bus connection
  83
• 1.5 Connector contact assignment on dash panel insert with data bus connection
  86
• 2 Service interval display
  88
• 2.1 Service interval display
  88
• 2.2 Service interval display for dash panel inserts without data bus connection
  88
• 2.3 Service interval display for dash panel inserts with data bus connection
  90
• 3 Tachograph >04.99
  92
• 3.1 Tachograph >04.99
  92
• 3.2 Connector contact assignment on tachograph instrument cowling
  93
• 3.3 Connector contact assignment on tachograph
  94
• 3.4 Tachograph05.00>
  94
• 3.5 Connector contact assignment on tachograph
  94
• 3.6 Removing and installing tachograph
  96
• Windscreen wipe and wash system
  98
• 1 Windscreen wiper system
  98
• 1.1 Windscreen wiper system
  98
• 1.2 Overview of windscreen wiper system
  98
• 1.3 Setting park position
  101
• 1.4 Adjusting wiper blade park position
  101
• 1.5 Removing and installing wiper blade rubber
  102
• 2 Windscreen washer system
  103
• 2.1 Windscreen washer system
  103
• 2.2 Windscreen washer system (short front end)
  103
• 2.3 Overview of windscreen washer system
  103
• 2.4 Removing and adjusting spray jets
  104
• 2.5 Hose connections on the windscreen washer pump
  105
• 3 Windscreen washer system (long front end)
  106
• 3.1 Windscreen washer system (long front end)
  106
• 3.2 Overview windscreen washer system
  106
• 3.3 Removing and adjusting spray jets
  107
• 3.4 Hose connections on the windscreen washer pump
  107
• 3.5 Removing and installing windscreen washer system fluid reservoir
  108
• 4 Servicing rear window wipe and wash system (tailgate)
  109
• 4.1 Servicing rear window wipe and wash system (tailgate)
  109
• 4.2 Overview of rear window wipe and wash system
  109
• 4.3 Adjusting park position
  112
• 4.4 Adjusting rear window wiper rest position
  112
• 4.5 Adjusting washer jets
  112
• 5 Servicing rear window wipe and wash system (wing doors)
  113
• 5.1 Servicing rear window wipe and wash system (wing doors)
  113
• 5.2 Overview of rear window wipe and wash system
  113
• 5.3 Adjusting parking position
  116
• 5.4 Adjusting rear window wiper rest position
  117
• 5.5 Adjusting washer jets
  117
• 6 Headlight washer system
  118
• 6.1 Headlight washer system
  118
• 6.2 Overview of headlight washer system
  118
• 6.3 Removing and installing spray nozzle holders
  120
• 6.4 Removing and installing lift cylinder for spray nozzles
  121
• 6.5 Adjusting washer jets
  122
• Lights, Lamps, Switches - exterior
  124
• 1 Headlight (short front end)
  124
• 1.1 Headlight (short front end)
  124
• 1.2 Assembly overview: Headlight
  124
• 1.3 Replacing headlight bulb
  127
• 1.4 Removing and installing headlight
  127
• 1.5 Removing and installing headlight range control positioning motor
  128
• 1.6 Adjusting headlights
  129
• 2 Headlight (long front end)
  130
• 2.1 Headlight (long front end)
  130
• 2.2 Assembly overview: Headlight
  130
• 2.3 Replacing headlight bulb
  132
• 2.4 Removing and installing headlight inserts
  132
• 2.5 Removing and installing headlight range control positioning motor
  133
• 2.6 Adjusting headlights
  134
• 3 Fog light (short front end)
  135
• 3.1 Fog light (short front end)
  135
• 3.2 Removing and installing front fog lights
  135
• 3.3 Replacing front fog light bulb
  135
• 3.4 Adjusting fog lights
  136
• 4 Fog light (long front end)
  136
• 4.1 Fog light (long front end)
  136
• 4.2 Removing and installing front fog lights
  136
• 4.3 Replacing front fog light bulb
  137
• 4.4 Adjusting fog lights
  137
• 5 Front turn signals (short front end)
  138
• 5.1 Front turn signals (short front end)
  138
• 5.2 Removing and installing front turn signals
  138
• 5.3 Replacing turn signal bulb
  138
• 6 Front turn signals (long front end)
  139
• 6.1 Removing and installing front turn signals
  139
• 6.2 Replacing turn signal bulb
  139
• 7 Tail lights
  140
• 7.1 Tail lights
  140
• 7.2 Removing and installing tail lights on delivery van
  140
• 7.3 Removing and installing tail lights on Dropside
  142
• 8 Additional brake light
  144
• 8.1 Additional brake light
  144
• 8.2 Removing and installing additional brake light bulb holder (tailgate)
  144
• 8.3 Removing and installing additional brake light housing (tailgate)
  145
• 9 Number plate lights
  145
• 9.1 Number plate lights
  145
• 9.2 Removing number plate lights
  145
• 10 Rear fog light
  146
• 10.1 Rear fog light
  146
• 10.2 Removing rear fog light
  146
• 11 Steering column switch and starter/ignition switch
  147
• 11.1 Steering column switch and starter/ignition switch
  147
• 11.2 Steering column overview
  147
• 11.3 Removing and installing steering column switch
  149
• 11.4 Removing and installing steering column switch housing
  150
• 11.5 Removing and installing lock cylinder
  151
• 11.6 Wiring connections on steering column switch and ignition/starter switch
  151
• Lights, Lamps, Switches - interior
  154
• 1 Immobilizer
  154
• 1.1 Immobilizer
  154
• 1.2 Removing and installing immobilizer
  154
• 1.3 Removing and installing immobilizer control unit
  155
• 1.4 Removing and installing immobilizer reading coil -D2-
  155
• 1.5 Transponder
  155
• 2 Fuel cut-off valve control unit
  156
• 2.1 Fuel cut-off valve control unit
  156
• 2.2 Assembly overview of fuel cut-off valve control unit
  156
• 2.3 Removing and installing fuel cut-off valve control unit
  157
• 2.4 Adapting fuel cut-off valve control unit to immobilizer control unit
  161
• 2.5 Immobilizer functional check
  161
• 3 Interior lights and switches
  162
• 3.1 Interior lights and switches
  162
• 3.2 Removing and installing light switch
  162
• 3.3 Removing and installing headlight range control adjuster -E102-
  162
• 3.4 Removing and installing switches in centre of dash panel
  162
• 3.5 Removing and installing hazard warning switch
  163
• Wiring
  165
• 1 Relay plate
  165
• 1.1 Relay plate
  165
• 1.2 Removing and installing relay plate
  165
• 1.3 Removing and installing multi-pin plug behind relay plate
  166
• 2 Wiring harness and connector repair
  167
• 2.1 Wiring harness and connector repair
  167
• 2.2 Safety remarks:
  167
• 2.3 General remarks concerning vehicle electrics repairs
  168
• 2.4 Remarks concerning wiring harness and connector repairs
  168
• 2.5 Wiring harness repair set V.A.G 1978
  169