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Polo Lim IN 2011 ➤, Polo Lim IN 2016 ➤, Polo Lim MY 2014 ➤, Polo Lim MY 2016 ➤, Polo Lim RUS 2011 ➤, Polo Lim RUS 2016 ➤, Polo Lim RUS 2020 ➤, Polo Variant 1998 ➤, Scirocco 2009 ➤, Scirocco 2015 ➤, Sharan 1996 ➤, Sharan 2011 ➤, Sharan 2016 ➤, T-Cross 2019 ➤, T-Roc 2018 ➤, T-Roc Cabriolet 2020 ➤, Taigun 2022 ➤, Tiguan 2008 ➤, Tiguan 2016 ➤, Tiguan 2021 ➤, Tiguan MEX 2017 ➤, Tiguan RUS 2017 ➤, Tiguan RUS 2021 ➤, Touareg 2003 ➤, Touareg 2010 ➤, Touareg 2015 ➤, Touareg 2018 ➤, Touran 2003 ➤, Touran 2016 ➤, Virtus 2022 ➤, XL1 2015 ➤, e-Golf 2014 ➤, e-Golf 2017 ➤, e-up! 2014 ➤, e-up! 2017 ➤, e-up! 2020 ➤, up! 2012 ➤, up! 2017 ➤, up! 2020 ➤
Electrical system, General information
Edition 01.2023
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List of Workshop Manual Repair Groups
Repair Group
27 - Starter, current supply, CCS
90 - Gauges, instruments
92 - Windscreen wash/wipe system
94 - Lights, bulbs, switches - exterior
96 - Lights, bulbs, switches - interior
97 - Wiring
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Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.
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1.3 Warning notices and safety regulations
1.4 Battery load test
2.1 Checking
2.2 Visual inspection
2.3 Information about battery replacement and battery gas venting
To ensure long use of the battery, the battery must be checked, serviced and maintained according to the specifications in this manual.
Apart from supplying energy for starting the engine, the battery has other tasks: it acts as a buffer and supplies electrical ener‐gy to the complete electrical on-board supply of the vehicle.
This battery is equipped with a colour indicator. The colour indicator provides information about the electrolyte level and the charge state of the battery. Checking the colour indicator ⇒ page 10
1.2.2Battery with »enhanced« colour indica‐tor
This is a maintenance-free battery with liquid electrolyte (wet battery).
The battery is used for particular requirements in certain vehi‐cles equipped with a start/stop system. The battery can be iden‐tified by the lettering “EFB” on the battery cover. “EFB” stands for »enhanced flooded battery«.
An “EFB” battery may only be replaced with another “EFB” bat‐tery.
The “EFB” battery has a colour indicator to enable the electro‐lyte level to be checked.
Checking the colour indicator ⇒ page 10
Note
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Maintenance-free battery with a contained electrolyte and no colour indicator
Lead-acid battery where the electrolyte is contained within a microscopic glass mat (AGM). The battery is sealed and fitted with valves.
AGM is the abbreviation for Absorbent Glass Mat.
Due to containment of the electrolyte, this type of battery cannot have a colour indicator. Absorbent glass mat batteries are iden‐tified by the abbreviation AGM on the battery.
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–Adapt battery ⇒ Vehicle diagnostic tester.
1.2.4Lithium ion battery
A visual inspection and classification is possible on this battery type.
Visual inspection and classification of 48 V battery -A6-.
–Rate the condition of the battery using vehicle diagnostic tester under 0021 Battery management 2.
Visual inspection and classification of additional battery for coasting function -A8-.
–Rate the condition of the battery using vehicle diagnostic tester under 0080 Additional battery for coasting function.
1.3Warning notices and safety regulations
⇒ w1.3.1 hen handling vehicle batteries”, page 3
⇒ m1.3.2 arkings on battery”, page 4
⇒ o1.3.3 n airbag system”, page 5
1.3.1Dangers when handling vehicle batter‐ies
Recognition and avoidance of dangers
Batteries can be dangerous. These dangers can be avoided when the warnings on the battery, in the operating manual and in ELSA are observed.
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1. - Fires, sparks, naked flames and smoking are prohibited when handling batteries. Avoid sparks as well as electrostatic discharge when working with cables and electrical units. Avoid short circuits. Therefore never lay a tool on a battery.
2. - Wear eye protection before commencing work on battery.
3. - Keep children away from acid and batteries.
4. - Disposal: old batteries are classed as hazardous waste. They may only be disposed of through a suitable collection centre and only in accordance with respective legislation.
5. - Never dispose of old batteries in household waste system!
6. - There is a danger of an explosion when working with bat‐teries. A highly explosive gas is produced when batteries are charged.
7. - Always follow instructions on battery, in ELSA "Electrical System, General Information" and in owner's manual.
8. - Battery acid is very caustic; therefore wear eye protection and gloves when working with batteries. Do not tilt battery. Acid can leak out of the gas vents of some batteries.
1.3.3Working on airbag system
WARNING
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Whenworkisperformedontheairbagsystem(pyrotechnical components,airbagcontrolunit-J234-,wiring)thebattery earthstrapmustbedisconnectedwiththeignitionswitched on.
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It is essential first to visually check the external condition, the terminals of the battery, the plugs of the gas vent openings and that the battery is seated securely before performing more extensive tests.
♦ If battery housing is damaged Electrolyte can leak out if the housing is damaged. If battery acid leaks out, serious dam‐age to the vehicle could be caused. Treat components affec‐ted by leaked battery acid immediately with acid neutraliser or a soap solution.
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♦ Check whether the battery terminals (battery wire connec‐tions) are damaged. The necessary contact on the battery terminal clamps cannot be guaranteed if the battery termi‐nals are damaged. When connecting the battery clamps, tighten the battery clamps to torque specified in this work‐shop manual “Electrical system” for the respective vehicle. If the battery terminal clamps are not correctly seated and tightened, the wiring may burn. Which will cause malfunc‐tions in the electrical system. Therefore it can no longer be guaranteed that the vehicle will function correctly.
♦ Whether the gas vent hose and the plug are fitted correctly. On vehicles with batteries in the passenger compartment or luggage compartment, it is essential to ensure that the gas vent hose is fitted correctly. Make sure that there are no exposed gas vent openings in the area of the positive battery terminal. If a gas vent opening is exposed in this area, it must be sealed with a plug. The gas vent hose must be connected in the area of the negative battery terminal to the exposed gas vent opening. Observe chapter ⇒ a2.3 bout battery replacement and battery gas venting”, page 9
2.3Information about battery replacement and battery gas venting
♦ For safety reasons, it is important to determine which side of the battery gas is vented from.
♦ For areas of application in which a gas vent hose is used, ensure that the gas vent hose is seated securely and that the gas vent opening on the opposite side is sealed.
♦ When renewing the vehicle battery, make absolutely sure that the gas vent opening in the area of the positive battery terminal is not exposed. Should a vent opening be exposed in this area, it must be sealed with a plug and the vent in the area of the negative battery terminal must be opened.
♦ If the vehicle is installed with an AGM battery outside the engine compartment, ensure that the battery is replaced with a different AGM battery.
♦ If the AGM battery is renewed, the battery monitor control unit -J367- must be adapted.
♦ Connect vehicle diagnostic tester.
♦ Adapt battery monitor control unit -J367- ⇒ Vehicle diagnos‐tic tester.
♦ For launch of the Passat 3C (2006), the gas vent opening is always on the negative battery terminal side.
♦ If there is a protective cap with sprayed on plug on the battery positive terminal of the replacement part battery 000.915.105.DX, with the exception of 000.915.105.DN and all Economy batteries with single index, this must also be changed on the negative battery terminal or positive battery terminal side according to the situation. A list of batteries can be found here ⇒ page 9
♦ AGM, EFB+, EFB batteries and the 36AH battery with origi‐nal part no.: 000.915.105.DN, installed e.g. in the up! and Polo, have a protective cap without moulded-on plug at the positive battery terminal. The gas vent on the positive bat‐tery terminal side is already sealed here.
If a genuine replacement part battery is discovered with the following part numbers, a red sealing plug must be fitted either on the positive or negative battery terminal side. If this is not installed, it must be retrofitted - genuine part no.: 000.915.506
List of batteries with protective cap and sprayed on plug OES wet:
♦ “36 Ah” 000.915.105.DA
♦ “44 Ah” 000.915.105.DB
♦ “51 Ah” 000.915.105.DC
♦ “60 Ah” 000.915.105.DD
♦ “61 Ah” 000.915.105.DE
♦ “72 Ah” 000.915.105.DG
♦ “80 Ah” 000.915.105.DH
♦ “85 Ah” 000.915.105.DJ
♦ “95 Ah” 000.915.105.DK
♦ “110 Ah” 000.915.105.DL
♦ “36 Ah” 000.915.105.DN
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Applies for all batteries with “1J0”, “7N0” and “3B0” indexes in original equipment and for all replacement batteries 191 915 105 AB and from “000 915 105 AX” index.
The colour indicator provides you with information about the electrolyte level and charge state of the battery.
Before carrying out a visual check, tap the inspection window lightly and carefully using the handle of a screwdriver. The air bubbles, which can influence the display, will dissipate when doing this. This will make the colour indicator reading more accurate.
Note
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The general introduction of the “2-colour” display took place gradually in 2009. The “2-colour” indicator does not include the colour »green« for indicating the charge level.
The colour indicator provides you with information on the elec‐trolyte level of the battery.
The battery charge can no longer be ascertained by means of the colour indicator; the battery has to be checked for this.
Before carrying out a visual check, tap the magic eye lightly and carefully using the handle of a screwdriver. The air bubbles, which can influence the display, will dissipate when doing this. The colour display of the magic eye will therefore be more accurate.
To quickly ascertain the state of discharged batteries, the bat‐tery current draw test whilst charging helps to determine wheth‐er the battery must be replaced or fully recharged.
The current draw test should always be carried out if
♦ The result of the test with battery tester with printer -VAS 6161- gave the following result:
1 - Perform current draw test
Performing a current draw test whilst charging the battery will quickly establish whether a partly or fully discharged battery ⇒ page 14 can be recharged to return it to a serviceable condi‐tion.
Test requirements:
♦ When charging the battery, its temperature must be at least ≥ +10°C.
♦ The charger must be capable of outputting a charge current of at least 30 A, as for example with VAS 5095A, VAS 5900, VAS 5903
♦ The battery's current draw must be measured with a current pick-up clamp, e.g. VAS 5051B/7, when charging with bat‐tery charger -VAS 5095A-. Battery charger -VAS 5900- and battery charger -VAS 5903- display the current draw on the
unit. Battery charger -VAS 5900- performs the current draw test automatically with menu guidance.
–Connect battery to battery charger and start charging se‐quence.
–Measure charge current of battery after 5 minutes.
Test result:
If the current draw A is higher than 10% of the nominal capacity (e.g. > 6.1 A for a 61 Ah battery), fully charge battery and test again.
–Fully charge the battery when the charge current is higher than 10% of the nominal capacity (observe exception for Eos in above note).
–Perform battery test after allowing battery to rest for two hours.
If the charge current, in amperes, lies below 10% of the nominal capacity after 5 minutes of starting the charging sequence (5% for the 2 × 6 volt batteries in Eos) (example for 50 Ah battery < 5 A), renew battery. For warranty and goodwill cases, please complete the battery test sheet. Ameo 2017 ➤, Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Atlas ... Electrical system, General information - Edition 01.2023
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92 –Windscreen wash/wipe system
1Washer fluid line hose couplings
The following hose coupling types are used to connect the hose connection to pumps and washer jets and/or as points of sepa‐ration:
1.1Windscreen and rear window washer system
–Pull the two coupling sections apart (no securing device) to loosen the connection.
–To secure the connection, push the two coupling sections together, until you hear and feel them engage.
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–To loosen the connection, rotate the lock ring -1- 90° -arrowand pull off the hose connection.
–To secure the connection, push on the hose connection and rotate the lock ring -1- -arrow- until it engages.
–To loosen the connection, pull up the lock ring -1- by approx. 1 mm -arrow-, and pull off the hose connection.
–To secure connection, attach hose connection and press in clip -1- until it engages.
–To loosen the connection, pull up the lock ring -1- -arrowand pull off the hose connection.
–To secure connection, attach hose connection and press in clip -1- until it engages.
1.2Headlight washer system
–To loosen the connection, push the lock ring -1- -arrow- and pull off the hose connection.
–To secure the connection, push and hold the lock ring -arrow- and push on the hose connection. Check that the securing clip has correctly engaged by depressing and trying to pull off without the clip.
A new repair concept has been developed for repair work on wash system hoses. Various connectors, special EPDM hoses (ethylene-propylene-diene monomer) and heat-shrink hose are available as spare parts.
2.1General description
♦ The replacement parts can be found in the electronic parts catalogue (ETKA).
♦ Replacement parts are available for repair of both smooth and corrugated pipes.
2.2Repairing smooth pipe
Smooth pipes with a diameter of 5x1 mm or 6x1 mm can be repaired with EPDM hose.
–Cut damaged section at right angles out of smooth pipe which is to be repaired.
–Select the appropriate EPDM hose -2- and cable ties ac‐cording to the electronic parts catalogue (ETKA).
–Cut EPDM hose -2- so that ends -1- and -3- of smooth pipe can each be pushed about 10 mm into the EPDM hose -2-.
GAnegawskloVybthgirypoC.tnemucodsihtninoitamrof –Push heat-shrink hose over corrugated tube, join connectors and secure repair joints with heat-shrink hose.
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3Distinguishing features of jointless wiper blades
Distinguishing features of Bosch and Federal Mogul products. When renewing wiper rubbers, note the make. When renewing wiper blades, the same make must be used.
Wiper blades can be identified according to wiper arm fasten‐ing.
Bosch wiper blades -1 and 2-:
Federal Mogul wiper blades -1-: Ameo 2017 ➤, Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Atlas ... Electrical system, General information - Edition 01.2023
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Duetothehighvoltage(above28000Vwhenignitingthe gas discharge bulb) and high temperatures, the gas dis‐chargebulbmustonlybeoperatedintheheadlighthousing.
Refer to removing and installing cigarette lighter -U1- ⇒ page 28
1.2Removing and installing socket illumi‐nation bulb -L42-
The removal of the socket illumination bulb -L42- is performed in the same way as the removal of the cigarette lighter illumina‐tion bulb -L28- ⇒ page 33 Ameo 2017 ➤, Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Atlas ... Electrical system, General information - Edition 01.2023
The following descriptions apply to the rear left cigarette lighter -U3-, rear right cigarette lighter -U7-, rear cigarette lighter -U9-, 12 V socket 2 -U18-, 12 V socket 3 -U19-, 12 V socket 4 -U20-, cigarette lighter 2 -U25- and 12 V socket 5 -U26- so far as they are illuminated.
On some vehicles, the illumination is not provided by a light bulb, but by an LED (light-emitting diode), depending on the equipment level. This LED is permanently attached to the re‐taining sleeve and cannot be renewed separately.
Retaining sleeves with a light bulb are available in different ver‐sions. On the one version, the light bulb can be replaced sepa‐rately; on the other version, the light bulb cannot be replaced separately. In this case, the bulb carrier has to be replaced together with the light bulb.
Depending on the space requirement, the vehicles are equip‐ped with various electric sockets and cigarette lighter sockets. They differ in length and have different electrical connections. In the case of electric sockets or cigarette lighter sockets with a wiring tail, it may be necessary to perform additional work in order to gain access to the connector.
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–Release puller locking lugs by pressing spindle -1- in direc‐tion of -arrow B-. Then release puller -2- by turning it briefly to left -arrow A-. Remove puller from socket.
♦ Observe the latest notes in the respective workshop manual when carrying out repairs.
♦ Observe country-specific regulations.
♦ Always disconnect the battery earth strap before working on the electrical system. Disconnecting the battery earth strap (open circuit) provides a safe working environment for re‐pairs to the electrical system. The battery positive wire need only be disconnected for removal of the battery.
♦ Before starting a repair, it is important to identify and rectify the cause of damage (e.g. sharp edges on body panels, defective electrical components, corrosion, etc.).
♦ For additional information, e.g. removal and installation of individual components, please refer to the relevant workshop manual.
♦ Soldering is not permitted for repairs to vehicle wiring.
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♦ Wiring harness and connector repairs to vehicle electrical system should be carried out using wiring harness repair set -VAS 1978 B- and previous versions only. Only use yellow wires from wiring harness repair set -VAS 1978 B-.
♦ Wiring harness repairs may not be integrated in the vehicle's own wiring harness and must be marked with the use of yellow adhesive tape. This indicates a previous repair.
♦ Crimp connectors may never be repaired. If necessary, lay wiring parallel to the defective wiring. After crimping, the crimp connector has to be shrink fitted using the hot air blower in order to prevent any ingress of moisture.
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♦ It is essential that the supplementary information is observed regarding repairs to wiring harnesses in airbag and belt ten‐sioner systems, fibre optic cables, CAN bus lines, aerial ca‐bles and wiring with cross sections up to 0.35 mm2 ⇒ page 54
♦ Carry out a function test after every repair. It may be neces‐sary for the fault memory to be interrogated, erased and/or for the systems to be reset.
♦ If possible, do not loosen any earth wires from the body (danger of corrosion).
♦ Wiring harness repair set -VAS 1978 B- and previous ver‐sions do not cover all wiring cross sections that occur in the vehicle. If the required wiring cross section is not available, the next largest one should be used.
♦ Screened wires can be repaired. Wiring for camera systems are the exception. If damaged they must be replaced com‐plete.
♦ Heat resistant wiring can be found in various places in the vehicle, mainly in the engine compartment. Heat resistant wiring can be identified by its slightly matt and softer insula‐tion. To repair these wires, only heat resistant wiring may be used.
2.2Wiring harness repair set
2.2.1Wiring harness repair set -VAS 1978-
Wiring harness repair set -VAS 1978- allows optimal repair quality to be achieved in the area of vehicle electrics. Using the tools, repairs to connectors and wiring open circuits can be carried out. To do this, complete repair wire sections with contacts already crimped on are used and joined to the vehi‐cle's own wiring harness with the aid of crimp connectors. A special set of pliers with three different crimp recesses and a hot air blower for shrinking the crimp connectors make a perfect electrical connection.
Note
Additionalinformation:
⇒ Operating instructions Wiring harness repair set -VAS 1978-
2.2.2Upgrade kit -VAS 1978/50-
Upgrade kit -VAS 1978/50- is required to bring the “old” wiring harness repair set -VAS 1978- up to the latest standard of wir‐ing harness repair set -VAS 1978A-. The upgrade kit comprises of 4 assembly and 10 release tools, a new set of crimping pliers for crimp connectors with head adapter 0.35 - 2.5 mm2 -VAS
1978/1-1-, 4.0 - 6.0 mm2 -VAS 1978/2 A- and head adapter for JPT contacts -VAS 1978/9-1-. Also included are new stickers, a new set of operating instructions, crimp connectors for 0.35 mm2 cable cross-section and a roll of black felt adhesive tape.
2.2.3Wiring
harness repair set -VAS 1978A-
The new wiring harness repair set -VAS 1978A- allows optimal repair quality to be achieved in the area of vehicle electrics. Using the new pliers, repairs to connectors and wiring open circuits can be carried out. To do this, complete repair wire sections with contacts already crimped on are used and joined to the vehicle's own wiring harness with the aid of four different types of crimp connectors. A new set of crimping pliers with head adapters and a hot air blower for shrinking the crimp con‐nectors make a perfect electrical connection.
Note
Additionalinformation:
⇒ Operating instructions Wiring harness repair set -VAS 1978A-
2.2.4Release tool set -VAS 1978/35-
Release tool set -VAS 1978/35- serves as a means of releas‐ing various primary and secondary locking devices in Group vehicles. The set comprises of 26 different tools with which, for example, round connector systems, flat contacts with one or two fasteners and also single wire seals can be released or fitted.
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Allocation of the correct release tool to the respective locking devices can be gleaned from the table in the ⇒ operating in‐structions of -VAS 1978/35-.
2.3Tool descriptions
2.3.1Special pliers with insert
The special pliers without insert -VAS 1978/1- with insert for special pliers -VAS 1978/2- is part of the wiring harness repair set -VAS 1978- and is used to crimp connectors during wiring harness repairs.
The various release tools serve as a means of detaching the different contacts from the contact housings without damage.
A selection of release tools is included in wiring harness repair set -VAS 1978- and wiring harness repair set -VAS 1978A-. The complete set of release tools is included in release tool set -VAS 1978/35- ⇒ page 41
Releasing and dismantling contact housings ⇒ page 104
2.3.3Assembly
tools for single wire seals
The assembly tools serve as a means of sliding the single wire seals fully into the contact housing without damage and thereby assure complete sealing between single wire and contact hous‐ing.
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Four assembly tools for single wire seals are included in each wiring harness repair set -VAS 1978 B- and previous versions.
Assembling single wire seals ⇒ page 100
2.3.4Wire
stripper -VAS 1978/3-
Wire strippers -VAS 1978/3- serve as a means of stripping insu‐lation off wires and cutting wires in the correct manner.
Wire strippers -VAS 1978/3- are included in wiring harness re‐pair set -VAS 1978 B- and previous versions.
The wire strippers have an adjustable limit stop within the pliers jaws, with which the desired length of insulation to be removed can be adjusted.
Stripping:
–Adjust the sliding limit stop in the pliers jaws to the desired length of insulation to be removed.
–Insert the end of the wire from the front fully into the pliers jaws and squeeze the pliers together completely.
–Open the pliers and removed the stripped wire end.
–Cut the wire if necessary with the cutting part on the upper side of the wire strippers.
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The hot air blower, 220 V / 50 Hz -VAS 1978/14- is used in con‐junction with shrink element for hot air blower -VAS 1978/15to shrink fit the crimp connectors. After crimping, the crimp con‐nector has to be shrink fitted using the hot air blower in order to prevent any ingress of moisture.
Hot air blower, 220 V/50 Hz -VAS 1978/14- is included in wiring harness repair set -VAS 1978 B- and previous versions.
Shrink fitting crimp connectors using hot air blower, 220 V / 50 Hz -VAS 1978/14- ⇒ page 72 , or ⇒ page 75
2.3.6Crimping pliers -VAS 1978/1A-
Crimping pliers -VAS 1978/1A- or crimping pliers (base tool) -VAS 1978/1-2- together with head adapter 0.35 - 2.5 mm² -VAS 1978/1-1- or head adapter 4.0 - 6.0 mm² -VAS 1978/2Aare used to squeeze together crimp connectors from the wiring harness repair sets.
Crimping connectors using crimping pliers -VAS 1978/1A- ⇒ page 75
The following heads adapters are available for crimping pliers (base tool) -VAS 1978/1-2-:
In conjunction with head adapter for JPT contacts -VAS 1978/9-1-, the crimping pliers are used to crimp contacts to single wires during repairs to wiring with cross sections up to 0.35 mm2 ⇒ page 54
Interchanging head adapter:
–Open up the crimping pliers fully.
–Unclip both locking pins -arrows- from the body of the crimp‐ing pliers.
–Insert the required head adapter from above -arrow- in the body of the crimping pliers.
–Lock the head adapter by engaging the pins -arrows- in the body of the crimping pliers.
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t2.4.1 o airbag and belt tensioner wiring”, page 47
⇒
C2.4.2 AN bus wiring”, page 49
⇒ o2.4.3 f Flexray wires with sheath”, page 50
⇒
o2.4.4 f Flexray wires without sheath”, page 51
⇒
o2.4.5 f aerial wiring”, page 52
⇒
02.4.6 .13 mm2/0.35 mm2/0.5 mm2 wire”, page 54
⇒ o2.4.9 pen circuit with one repair position”, page 72
⇒ o2.4.10 pen circuit with two repair positions”, page 75
⇒ f2.5 ibre optic cables”, page 77
⇒ o2.6 f aerial wires”, page 86
2.4.1Repairs to airbag and belt tensioner wiring
In addition to the general notes on repairs to wiring harnesses, the following instructions must be observed on how to repair wiring in airbag and belt tensioner systems:
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Observe the following for repairs to the connectors of the airbag and belt tensioner unit:
The various connectors are only available as terminated cables. The repair connectors with cables always have the same cable colours. Pin 1 is black, pin 2 is yellow and, if present, pin 3 is brown.
See the current flow diagram for correct assignment of the ca‐bles ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
2.4.2Repairing CAN bus wiring
♦ Adhere to general instructions concerning repairs to vehicle electrical system ⇒ page 38 .
♦ An unshielded, twisted two-wire line -1- and -2- is used as a CAN bus wire.
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♦ When repairs are performed, both CAN bus wires must have the same length.
♦ It is not permitted to repair the individual cores.
♦ Repairs to CAN bus wires must be carried out observing the correct cross section.
♦ For allocation, refer to ⇒ Electronic parts catalogue (ETKA).
♦ The repair must not result in excess lengths.
♦ There must not be any section of wiring, for example in the vicinity of crimp connectors -arrow-, longer than -A- = 50 mm where the wires are not twisted.
♦ The area of repair is to be protected against environmental influences by suitable means. To do this, a crimp connector with heat-shrink hose and internal adhesive over the untwis‐ted repair area is to be used as well as waterproof insulating tape over the wire section stripped of sheath.
♦ The repair area is to be marked by suitable means, e.g. with yellow insulating tape.
♦ For repairs to two core wires, the same specifications as for repairs to single core wires are to be adhered to.
♦ In addition, both repair areas -arrows- are to be opposed by one twist length -A- = 30 mm in relation to each other.
♦ The crimping of cable ends with connectors is to be carried out analogously.
1 - Repair area in stripped section
2 - Repair area with connector-attached cable ends
♦ Replacement parts can be found in the ⇒ Parts catalogue (ETKA): Special catalogue; Electrical connections; Genuine accessories; Subgroup 35 from illustration No. 035-20.
♦ These genuine parts are suitable for all aerial wires and wire diameters which may need to be replaced.
♦ The connector housings for aerial wires are only available as genuine parts in one colour. However, they can be used for all colours of aerial connector.
♦ No provision has been made for replacement of individual aerial connectors in the event of repair.
♦ The wires can be used retroactively for all VW models, with all installed aerial wire diameters.
♦ All adapter and connection wires are suitable for all transmit‐ter and receiver signals.
♦ This repair method can also be used for testing or retrofit‐ting.
Assembly overview of aerial cable:
Example: aerial wire between radio and aerial is defective. The following wires are required for the repair:
1 -Adapter cable, to radio connection. Length approx. 30 cm.
2 -Connecting wire, available in different lengths.
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3 -Adapter cable, to aerial connection. Length approx. 30 cm.
–To determine the length of connecting wire required, sub‐tract 60 cm from the measured total length of aerial connect‐ing wire -2-.
–Procure the required adapter cables -1- and -3- and con‐necting wire -2- at length calculated as genuine part from the Electronic parts catalogue (ETKA).
–Cut off connectors of defective aerial wire.
The remainder of the defective aerial wire remains in the vehi‐cle.
–Connect adapter cables -1- and -3- to equipment in vehicle.
–Route and attach the connection line -2- in the immediate vicinity of the factory routing.
–Fit adapter head 0.13 - 0.5 mm² -VAS 1978/1-3- -1- on crimping pliers (body) -VAS 1978/1-2- as follows:
–Open crimping pliers -VAS 1978/1-2-.
–Pull out locking pins -2- in direction of -arrow A- as far as stop.
–Fit adapter head -VAS 1978/1-3- -1- centrally on crimping pliers -VAS 1978/1-2- in direction of -arrow B-.
–Insert locking pins -2- again as far as stop.
–Clear the wire to be repaired about 20 cm either side of the repair position.
Caution
Riskofdamagetoelectricalwiring.
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♦ Carefullylaywrappedwiringharnessesaside.
–If necessary, remove wrapping of wiring harness.
–Cut out the damaged piece of wiring using side cutters.
– For 0.13 mm2 wires, position heat-shrink hose -1- centrally over crimp connector -2- by feeling contours.
• Dimension -a- must be approximately even on both sides.
–Heat up heat-shrink hose/crimp connector using hot air blower along a straight line, working from centre outwards, until it is sealed completely and adhesive escapes from the ends.
• This is how the finished repair point should look -3-.
–Insert the end of the wire from the front fully into the pliers jaws and squeeze the pliers together completely.
–Open the pliers and removed the stripped wire end.
• Insulation must be cut cleanly and removed from the wire
• Do not leave any insulation on the stripped wires
• Single wires must not be damaged
–Use a suitable butt connector and heat-shrink hose from wiring harness repair set -VAS 631 003- to perform repair.
–Push heat-shrink hose onto one of the wires.
–Position crimp connector -1- with first crimping point centrally on crimping anvil -2-.
• Dimension -a- must be even on both sides
–Turn quick-action lever -3- in anti-clockwise direction -arrowuntil butt connector -1- is secure.
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–Insert wire -2- with stripped end into butt connector -1- as far as stop -arrow-.
• All single wires must be pushed into the butt connector
–Close and open the crimping pliers several times until the crimping anvil moves downwards automatically to the start position.
Note
Theinsulationonthewiresmustnotbecrimped.
–Crimping the wire with butt connector on the other side as described.
–Pull out locking pin in direction of arrow -A- as far as it will go.
–Open adapter in direction of arrow -B-.
–Remove crimped crimp connector.
Correct crimping result
A - 10 mm2, star crimp
B - 16 mm2, B crimp
After crimping, the heat-shrink hose over the butt connector has to be shrink fitted using the hot air blower in order to prevent any ingress of moisture. Ameo 2017 ➤, Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Atlas ... Electrical system, General information - Edition 01.2023
–Position heat-shrink hose -1- centrally over butt connector -2- by feeling contours.
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• Dimension -a- must be roughly even on both sides
–Heat up heat-shrink hose using hot air blower along a straight line, working from centre outwards, until it is sealed completely and adhesive escapes from the ends.
• This is how the finished repair point should look -3-.
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–Choose the crimping anvil, crimping stamp and contact posi‐tioner with contact locking mechanism relevant to the wire thickness and attach to the hand pliers as follows:
–Open hand pliers from wiring harness repair set -VAS 631 001-.
–Pull out locking pin -1- to stop in direction of -arrow A-.
–Insert wire -2- with stripped end into butt connector -1- as far as stop -arrow-.
• All single wires must be pushed into the butt connector
• End of insulation should be no further than front edge of insulation crimp
–Close hand pliers until hand pliers open again automatically.
–Turn contact locking mechanism -2- onto stop in direction of -arrow-.
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–Remove crimp connector -1- from contact positioner -3-.
–Rotate hand pliers for 2nd crimping.
–Crimping the wire with butt connector on the other side as described.
–Pull out locking pin -1- in direction of arrow -A- as far as it will go.
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• End of wire must protrude 0.1 mm … 1.0 mm at front edge of wire crimp, dimension -a-
• End of insulation must not be crimped with wire crimp
• Insulation should end no further than front edge of insulation crimp -arrows-
After crimping, the heat-shrink hose over the butt connector has to be shrink fitted using the hot air blower in order to prevent any ingress of moisture.
–Fit shrink element for hot air blower -VAS 1978/15A- onto hot air blower -VAS 1978/14A-.
• Dimension -a- must be roughly even on both sides
–Heat up heat-shrink hose using hot air blower along a straight line, working from centre outwards, until it is sealed completely and adhesive escapes from the ends.
• This is how the finished repair point should look -3-.
After crimping, the crimp connector has to be shrink fitted using the hot air blower in order to prevent any ingress of moisture.
–Place shrink element for hot air blower -VAS 1978/15- on hot air blower, 220 V / 50 Hz -VAS 1978/14-.
–Heat up the crimp connector using the hot air blower along a straight line, working from the middle outwards, until it is sealed completely and the adhesive escapes from the ends.
Caution
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–Cut the damaged section of wire out of the vehicle's own single wire.
–Strip the wire ends of insulation by 6 - 7 mm using the wire strippers.
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–Push the crimp connector onto one side of the vehicle's own single wire and on the other side onto the repair wire.
–Crimp the connector using the crimping pliers to both wire ends.
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–Repeat this procedure on the other end of the repair wire.
–Place shrink element for hot air blower -VAS 1978/15- on hot air blower, 220 V / 50 Hz -VAS 1978/14-.
–Heat up the crimp connector using the hot air blower along a straight line, working from the middle outwards, until it is sealed completely and the adhesive escapes from the ends.
Caution
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It is very difficult to identify the exact location of the defect. Replace the damaged fibre optic cable by laying a new cable parallel to the defective fibre optic cable.
The repair set, aerial cable -VAS 6720- makes it possible to attain optimal repair quality in the repair of aerial wiring RG 174 (blue) and RKT 031 (black). The set includes the respective stripping tools and crimping tools for both aerial cables. In addi‐tion, the case includes all the separate parts needed to connect the Genuine plug in nearly production quality. In this case, only the 0-coded connector (green) is required. All other connecting wires for the various infotainment systems can be found in ET‐KA (EL-electrical connection elements) in plate 035-XX. These various adapter aerial wires are specific to vehicle models and must always be ordered separately. All the separate parts can be found in the above-named plate for reordering. The compart‐ments of the case are labelled with the part numbers of the consumable materials. The repair set is based on the existing adapters and pliers system of the VAS 1978B.
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–Push sleeve -2- and outer contact -1- over inner conductor. The knurled contact part of outer contact -1- must be pushed under shielding but over the aluminium foil. –Push on outer contact -3- completely. Ensure proper seating of female connector and pin.
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–Slide the single wire seal into the contact housing using the correct assembly tool ⇒ page 100
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–Trim the repair wire and the single wire of the vehicle's own wiring harness accordingly using wire strippers -VAS 1978/3-.
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–Strip the 6 - 7 mm of insulation from the end of the repair wire and the vehicle's own single wire using the wire strip‐pers.
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–Crimp the stripped ends of the repair wire and single wire of the vehicle's own wiring harness using the crimping pliers and a crimp connector, as described in the chapter entitled “Wiring open circuits with one repair position” ⇒ page 72
–Disengage the contact locking mechanism using the appro‐priate release tool -A- and then pull the wire with the single wire seal backwards -arrow- out of the contact housing. Ameo 2017 ➤, Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Atlas ... Electrical system, General information - Edition 01.2023
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–Slide the single wire seal -A- on the repair wire until it rea‐ches the contact housing.
–Slide the single wire seal -A- using the respective assembly tool -B- fully into the contact housing.
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–Trim the repair wire and the single wire of the vehicle's own wiring harness accordingly using wire strippers -VAS 1978/3-.
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–Crimp the stripped ends of the repair wire and single wire of the vehicle's own wiring harness using the crimping pliers and a crimp connector, as described in the chapter entitled “Wiring open circuits with one repair position” ⇒ page 72
Rep. gr.97 - Wiring
2.7.4Repairs to contact housings using cutand-clamp method
Allocation of the correct release tool to the respective locking devices can be gleaned from the table in the ⇒ operating in‐structions of -VAS 1978/35-.
2.8.2Secondary locking element
The secondary locking mechanism is a housing catch (second line locking mechanism) that secures all the wires in one con‐tact housing. If a secondary locking mechanism is fitted to a contact housing, this must always be opened or removed using the appropriate tool before releasing and pulling out individual crimp contacts.
The secondary locking mechanism is different in colour from the rest of the contact housing. This makes it easier to identify the secondary locking element and clarifies its intended function.
The types of contact housing shown here are just a few exam‐ples to show the different functions of secondary locking mech‐anism.
The housing catch is disengaged by removing a “toothed ele‐ment” -arrow-.
Example 2:
The housing catch is disengaged by opening a “flap” -arrow-.
Example 3:
The housing catch can be disengaged by detaching a “slide” -arrow-.
2.8.3Primary locking element
The primary locking mechanism is what fixes an individual crimp contact in the contact housing.
If necessary, any housing catches in place (secondary locking elements) must be released or removed prior to disengaging the contacts using the prescribed tool ⇒ page 104
The types of primary locking elements shown as follows are just a few examples to show the different functions of primary locking element.
♦ Round connector systems ⇒ page 106
♦ Flat connector systems ⇒ page 107
♦ Special connector systems ⇒ page 109
Allocation of the correct release tool to the respective locking device can be gleaned from the table in the ⇒ operating instruc‐tions of -VAS 1978/35-.
–The release tool can be pulled out of the contact housing again once the contact has been ejected.
Contacts without locking tabs:
–Insert the release tool under the locking tab of the contact housing.
–Push through the release tool with a light upward movement -arrow- onto the limit stop.
The contact is ejected from the contact housing.
3Contact surface cleaning set -VAS 6410-
3.1Using contact surface cleaning setVAS 6410-
The contact surface cleaning set -VAS 6410- enables optimal repair of the electrical systems and components in the vehicle. The tools allow performing repair work in the area of the sensor in wiring harnesses for threaded connections in the high-current circuit (starting and charge current). The contact surface clean‐ing set -VAS 6410- is matched to the structural features of the vehicles and ensures safe repairs while making the work easier at the same time.
–Loosen cap nut and remove ring terminal from threaded connection.
–Check ring terminal for corrosion, dirt etc.
–Select suitable adapter and suitable sanding pad.
Note
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–Set adapter on threaded connection and grind off corrosion and dirt with circular movements.
–Check threaded connection and regrind if necessary.
–Tighten connection and, if necessary, locating element again to specified torque ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
–Check battery clamp and battery terminal for corrosion or dirt.
–Clean battery clamp using wire brush of battery terminal cleaner with circular movements.
–Clean battery terminal using underside of battery terminal cleaner with circular movements. Ameo 2017 ➤, Arteon 2018 ➤, Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Atlas ... Electrical system, General information - Edition 01.2023
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–Place both Lambda probes next to each other so that the sensor housings are at the same height.
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–Tie back any excess in the uniform probe length (approx. 50 - 250 mm) to the size of the defective probe and secure with cable ties -1-.
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Only used on 4-pin LSF Lambda probes and 6-pin LSU Lambda probes.
Type D4, 12 openings at 1.4 mm each
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Only used on 4-pin LSF Lambda probes and 6-pin LSU Lambda probes.
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Workshop Manual
Eos 2006 ➤
Electrical system from 01.2011
Edition 11.2013
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List of Workshop Manual Repair Groups
Repair Group
27 - Starter, current supply, CCS
90 - Gauges, instruments
92 - Windscreen wash/wipe system
94 - Lights, bulbs, switches - exterior
96 - Lights, bulbs, switches - interior
97 - Wiring
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Technical information should always be available to the foremen and mechanics, because their carefulandconstantadherencetotheinstructionsisessentialtoensurevehicleroad-worthinessand safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.
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8.1 Treble horn H2 and bass horn H7
9.2 Immobilizer control unit J362
9.3 Immobilizer reader coil D2
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Eos 2006 ➤ Electrical system from 01.2011 - Edition 11.2013
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All the instructions and information for this manual are found in theworkshopmanual“ElectricalSystem,GeneralInformation”.A link to this workshop manual is not possible at present for tech‐nical reasons. Please select the workshop manual “Electrical System, General Information” manually in ELSA.
1.1Types of battery
All the instructions and information for this manual are found in theworkshopmanual“ElectricalSystem,GeneralInformation”.A link to this workshop manual is not possible at present for tech‐nical reasons. Please select the workshop manual “Electrical System, General Information” manually in ELSA.
1.2Warning notices and safety regulations
All the instructions and information for this manual are found in theworkshopmanual“ElectricalSystem,GeneralInformation”.A link to this workshop manual is not possible at present for tech‐nical reasons. Please select the workshop manual “Electrical System, General Information” manually in ELSA.
1.3Battery terminal connection
All the instructions and information for this manual are found in theworkshopmanual“ElectricalSystem,GeneralInformation”.A link to this workshop manual is not possible at present for tech‐nical reasons. Please select the workshop manual “Electrical System, General Information” manually in ELSA. Eos 2006 ➤ Electrical system from 01.2011 - Edition 11.2013
2006
Electrical system from 01.2011 - Edition 11.2013
2Checking battery
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Battery recharging or jump starting on vehicles with Start/Stop system:
Whenrechargingorjumpstartingvehicleswithstart/stopsystem, note the following: first connect charging cable to battery positive terminal, then body earth. This ensures that the battery monitor control unit - J367- (battery sensor) is not bridged. The direct chargingofthebatteryonthenegativeterminalclampmeansthat the battery sensor is shunted and the battery data are not regis‐tered by the sensor while charging. The values concerning the battery state saved in the data bus diagnostic interface do not then correspond to the values of the charged battery.
3.1Assembly overview
1 - Earth wire battery terminal clamp
❑Observe notes for bat‐tery terminal clamp bolt
⇒ page 1
❑Vehicles with start/stop system are fitted addi‐tionally with battery monitoring control unitJ367- (battery sensor). Observe notes
⇒ page 3
2 - Securing nut for earth wire battery terminal clamp
❑M6
❑6 Nm
3 - Positive wire battery termi‐nal clamp
❑Observe notes for bat‐tery terminal clamp bolt
⇒ page 1
4 - Securing nut for positive wire battery terminal clamp
Replacing battery on vehicles with start/stop system:
Becauseofitshigherdeep-cycleresistance,onlyaspecialstarter battery is used in vehicles with a start/stop system.
When renewing the starter battery, note correct part designation in ⇒ ETKA . Starter batteries for use in vehicles with a start/stop system are marked with “AGM” (Absorbent Glass Mat) or “EFB” (Enhanced Flooded Battery).
4.1Assembly overview
1 - Earth wire battery terminal clamp
❑Observe notes for bat‐tery terminal clamp bolt
⇒ page 1
❑Vehicles with start/stop system are fitted addi‐tionally with battery monitoring control unitJ367- (battery sensor).
Observe notes
⇒ page 3
2 - Securing nut for earth wire battery terminal clamp
❑M6
❑6 Nm
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3 - Positive wire battery termi‐nal clamp
❑Observe notes for bat‐tery terminal clamp bolt
⇒ page 1 .
4 - Securing nut for positive wire battery terminal clamp
❑M6
❑6 Nm
5 - Battery
❑ Removing and installing
⇒ page 7 .
6 - Clamping plate
7-Clampingplatesecuringnut
❑M8 x 35
❑35 Nm
4.2Removing and installing battery
Special tools and workshop equipment required
Electrical system from 01.2011 - Edition 11.2013
♦ Torque wrench - V.A.G 1331-
Removing:
–Disconnect battery ⇒ page 3 .
In vehicles with air filter housing above battery mounting:
– Remove air filter housing ⇒ Engine; Rep. gr. 23 or ⇒ Engine; Rep. gr. 24 .
Continuation for all vehicles:
– Depending on equipment, pull either panel off battery housing or fleece bag upwards in -direction of arrow- off battery.
–Unscrew securing bolt -1- and remove securing bar -2-.
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–Fold up handles -arrows- (if fitted) and remove battery up‐wards out of vehicle.
Installation is carried out in the reverse order. When installing ob‐serve the following:
– Tighten threaded connections to specified torque given in as‐sembly overview ⇒ page 7
–After installing battery, check it is firmly seated.
–Connecting battery ⇒ page 3 .
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Eos 2006 ➤
Electrical system from 01.2011 - Edition 11.2013
5Starter, vehicles with manual gear‐box
Replacing battery on vehicles with start/stop system:
Becauseofitshigherdeep-cycleresistance,onlyaspecialstarter battery is used in vehicles with a start/stop system.
When renewing the starter battery, note correct part designation in ⇒ ETKA . Starter batteries for use in vehicles with a start/stop system are marked with “AGM” (Absorbent Glass Mat) or “EFB” (Enhanced Flooded Battery).
When renewing starter, note correct part designations in ⇒ ET‐KA . Components adapted to start/stop system are not identified separately and are not or barely different from normal compo‐nents in their appearance.
5.2Starter, vehicles with 1.4 l, 90 kW TSI engine and manual gearbox MQ200-6F
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5.2.1Assembly overview - 1.4 l TSI engine with 90 kW, manual gearbox MQ200-6F
system from 01.2011 - Edition 11.2013
1 - Starter
❑ Removing and installing ⇒ page 11
❑Checking ⇒ page 10
2 - Battery positive wire con‐nection to starter
3 - Battery positive wire secur‐ing nut to starter
❑M8
❑20 Nm
4 - Starter securing bolts
❑M12
❑75 Nm
5 - Nut of earth cable
❑M8
❑20 Nm
6 - Protective cap
7-Wiringretainersecuringnut
❑M8
❑20 Nm
8 - Wiring retainer
Not illustrated
♦ Air filter housing securing bolt to body – 10 Nm
5.2.2 Removingandinstallingstarter,1.4lTSI engine with 90 kW, manual gearbox MQ200-6F
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
Eos 2006 ➤
Electrical system from 01.2011 - Edition 11.2013
♦ Torque wrench - V.A.G 1332-
Removing:
–Disconnect battery ⇒ page 3 .
– Remove air filter housing ⇒ Engine mixture preparation; Rep. gr. 24 ; Injection system; Removing and installing air filter .
–Release connector -1- and disconnect.
–Push protective cap -1- downwards off solenoid switch in -direction of arrow-.
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–Unscrew securing nut -1- and remove positive cable -2- from connecting thread of solenoid switch.
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• You can download the complete manual from: www.heydownloads.com by clicking the link below
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Eos 2006 ➤ Electrical system from 01.2011 - Edition 11.2013
5.5.2Removing and installing starter, vehi‐cleswith2.0lTDIengine,103kW,man‐ual gearbox MQ350
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
Electrical system from 01.2011 - Edition 11.2013
♦ Torque wrench - V.A.G 1332-
Removing:
–Disconnect battery ⇒ page 3 .
– Remove air filter housing ⇒ Engine mixture preparation; Rep. gr. 23;Dieseldirectinjectionsystem;Removingandinstalling air filter .
– Pushprotectivecapoffsolenoidswitchdownwardsindirection of -arrow-.
–Release connector of terminal 50 -2- and separate.
–Unscrew nut -arrow- from upper securing bolt of starter and remove underlying earth cable. Eos 2006 ➤
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–Unscrew securing nut -1- and remove underlying positive ca‐ble from connecting thread of solenoid switch.
–Remove upper securing bolt of starter -arrow-.
–Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 ; Body front; Noise insulation .
– Unscrew securing nut -1- and remove cable retainer from low‐er securing bolt of starter.
–Remove lower securing bolt of starter -arrow-.
–Remove starter from vehicle.
Installing:
Install in the reverse order of removal. When doing this, note the following:
– Tighten threaded connections to torque specified in assembly overview ⇒ page 20
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Eos 2006 ➤
Electrical system from 01.2011 - Edition 11.2013
6Starter, vehicles with dual clutch gearbox (DSG)
Replacing battery on vehicles with start/stop system:
Becauseofitshigherdeep-cycleresistance,onlyaspecialstarter battery is used in vehicles with a start/stop system.
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When renewing the starter battery, note correct part designation in ⇒ ETKA . Starter batteries for use in vehicles with a start/stop system are marked with “AGM” (Absorbent Glass Mat) or “EFB” (Enhanced Flooded Battery).
When renewing starter, note correct part designations in ⇒ ET‐KA . Components adapted to start/stop system are not identified separately and are not or barely different from normal compo‐nents in their appearance.
⇒ Current flow diagrams, Electrical fault finding and fitting loca‐tions
Fault detection and fault display:
Use ⇒ Vehicle diagnostic tester for fault finding ⇒ page 10
6.1Starter, 2.0 l TSI engine, 147 kW or 155KW,dualclutchgearboxDQ250-6F
6.1.1 Assembly overview - 2.0 l TSI engine, 147 kW or 155 KW, dual clutch gear‐box DQ250-6F
2006 ➤ Electrical system from 01.2011 - Edition 11.2013
1 - Starter
❑ Removing and installing ⇒ page 25
❑Checking ⇒ page 10
2 - Battery positive wire con‐nection to starter
3 - Battery positive wire secur‐ing nut to starter
❑M8
❑20 Nm
4 - Starter securing bolts
❑M12
❑75 Nm
5 - Protective cap
6 - Wiring retainer securing bolts
❑M8
❑23 Nm
7 - Wiring retainer
Not illustrated
♦ Air filter housing securing bolt to body – 10 Nm
6.1.2 Removingandinstallingstarter,2.0lTSI engine with 147 kW or 155 KW, dual clutch gearbox DQ250-6F
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Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
Starter, vehicles with dual clutch gearbox
Eos 2006 ➤
Electrical system from 01.2011 - Edition 11.2013
♦ Torque wrench - V.A.G 1332-
Removing:
–Disconnect battery ⇒ page 3 .
– Remove air filter housing ⇒ Engine mixture preparation; Rep. gr. 24 ; Injection system; Removing and installing air filter .
–Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 ; Assembly overview - noise insulation .
–Unscrew earth cable -arrow- from gearbox and lay to side.
– Pushprotectivecapoffsolenoidswitchdownwardsindirection of -arrow-.
–Release connector of terminal 50 -2- and separate.
–Unscrew securing nut -1- and remove underlying positive ca‐ble from connecting thread of solenoid switch.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
–Remove charge air hose -2- and charge air pipe -1- ⇒ 4-cyl‐inder injection engine (2.0 l turbocharged engine); Rep. gr. 21 ; Assembly overview - charge air cooling; Assembly over‐view - charge air cooling .
–Unscrew lower securing bolt -arrow- for starter.
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–Remove starter upwards from vehicle.
Installing:
Install in the reverse order of removal. When doing this, note the following: Eos 2006 ➤ Electrical system from 01.2011 - Edition 11.2013
– Tighten threaded connections to torque specified in assembly overview ⇒ page 24
6.2Starter, 2.0 l TDI engine with 103 kW, dual clutch gearbox DQ250-6F
6.2.1Assembly overview - 2.0 l TDI engine with 103 kW, dual clutch gearbox DQ250-6F
1 - Starter
❑ Removing and installing ⇒ page 29
❑Checking ⇒ page 10
2 - Battery positive wire con‐nection to starter
3 - Battery positive wire secur‐ing nut to starter
❑M8
❑20 Nm
4 - Starter securing bolts
❑M12
❑75 Nm
5 - Protective cap
2006 ➤ Electrical system from 01.2011 - Edition 11.2013
Not illustrated
♦ Air filter housing securing bolt to body – 10 Nm
6.2.2Removing and installing starter, 2.0 l TDI engine with 103 kW, dual clutch gearbox DQ250-6F
Special tools and workshop equipment required
♦Torque wrench - V.A.G 1331-
♦Torque wrench - V.A.G 1332-
♦Spring-type clip pliersVAS 5024-
Removing:
–Disconnect battery ⇒ page 3
– Remove air filter housing ⇒ Engine mixture preparation; Rep. gr. 23;Dieseldirectinjectionsystem;Removingandinstalling air filter .
Eos 2006 ➤
Electrical system from 01.2011 - Edition 11.2013
– Pushprotectivecapoffsolenoidswitchdownwardsindirection of -arrow-.
–Release connector of terminal 50 -2- and separate.
–Unscrew securing nut -1- and remove underlying positive ca‐ble from connecting thread of solenoid switch.
–Unclip line -1- from cable retainer -2-.
–Remove upper securing bolt of starter -arrow-.
. icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnot raccep
–Remove lower securing bolt of starter -arrow-.
–Remove starter upwards from vehicle.
Installing:
Install in the reverse order of removal. When doing this, note the following:
– Tighten threaded connections to torque specified in assembly overview ⇒ page 28 Eos 2006 ➤ Electrical system from 01.2011 - Edition 11.2013
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AGdoesnotguaranteeoracceptanyliabilitywi
Eos 2006 ➤
Electrical system from 01.2011 - Edition 11.2013
7Alternator
Alternator on vehicles with start/stop system:
Untilnowthealternatorandthevoltageregulatorwereconnected together via their own wires to the engine and onboard supply control unit. For vehicles with start/stop system, the information transmission occurs via a LIN data bus to the diagnostic interface fordatabus.ViatheCANdatabus,itsuppliesinformationtoother control units such as the engine control unit.
