Electrical System
Uploaded by
Diego AlvarezElectrical System
Uploaded by
Diego AlvarezService
Workshop Manual
California
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Service Department. Technical Information
Service
List of Workshop Manual Repair Groups
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00 - Technicaloridata
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27 - Starter,
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90 - Gauges, instruments
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92 - Windscreen wash/wipe system
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94 - Lights, bulbs, switches - exterior
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96 - Lights, bulbs, switches - interior
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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.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg D4B8055C9ED
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when using testing and measuring instruments during a road test . . . . 1
1.3 Operation and safety notes for gas discharge lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Battery - general notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Types of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
27 - Starter, current supply, CCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Assembly overview - battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Disconnecting and connecting battery . . . . . .G.. .V.ol.ks.w.a.ge. n. . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1.5 Removing and installing battery . . . .ol.ks.w.a.g . . . . . . . . . . . . . . .do. e.s.no. . . . . . . . . . . . . . . . . . . . 11
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1.6 Removing and installing batteryspartition db
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1.7 Removing and installing battery ut
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1.8 Removing and installing battery ss isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c. . . . . . . . . . . 16
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1.9 Removing and installing earth wire with battery monitor control unit J367 . . . . . . . . . . . . 17
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1.10 Adapting battery monitor control unit J367 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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2 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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2.1 Assembly overview - alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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2.2 Removing and installing alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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2.3 Checking alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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2.4 Checking poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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2.5 Removing and installing poly V-belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.6 Removing and installing voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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3 Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.1 Assembly overview – starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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3.2 Checking starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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3.3 Removing and installing starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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4 Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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5 Start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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5.1 General description - start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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5.2 Overview of fitting locations - start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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5.3 Removing and installing voltage stabiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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6 Adaptive cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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6.1 Overview of fitting locations - adaptive cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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6.2 Removing and installing automatic distance control unit . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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6.3 Removing and installing trim for radar sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.4 Calibrating adaptive cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
90 - Gauges, instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1 Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.1 Assembly overview - dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.2 Removing and installing dash panel insert KX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.3 Removing and installing ambient temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2 Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Contents i
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
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2.1 Removing and installing clock . . . . . . . . V. o.lk.sw . . . . . . . . . . . . . . . . . . e.s.no. t.g. . . . . . . . . . . . . 53
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3 Horn . . . . . . . . . . . . . . . . . . . . . . .o.ris.e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.e . . . . . . . . .
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3.1 Assembly overview - horn . . . . .au.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .o.r a.c . . . . . . 54
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3.2 Removing and installing horn ors dual tone horn H1 / bass horn H7 . . . . . . . . . . . . . . . . . . 54
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4 Tachograph “DTCO 1381” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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4.1 General description - tachograph “DTCO 1381” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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4.2 Overview of fitting locations - tachograph “DTCO 1381” . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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4.3 Removing and installing tachograph “DTCO 1381” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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4.4 Messages displayed on tachograph “DTCO 1381” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.5 Connector pin assignment - tachograph “DTCO 1381” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
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4.6 Removing and installing tachograph sender G75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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1 windscreen wiper system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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1.1 Assembly overview - windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.2 Moving wipers to service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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1.3 Removing and installing wiper blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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1.4 Removing and installing wiper arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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1.5 Adjusting wiper arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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1.6 Removing and installing wiper frame with linkage and wiper motor V . . . . . . . . . . . . . . . . 76
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1.7 Renewing wiper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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1.8 Removing and installing rain and light sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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2 Windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
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2.1 Assembly overview - windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pyri
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2.2 Removing and installing filler pipe for washer fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . 85
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2.3 Removing and installing washer fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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2.4 Removing and installing windscreen washer fluid level sender . . . . . . . . . . . . . . . . . . . . . . 89
2.5 Removing and installing windscreen washer pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.6 Removing and installing washer jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.7 Adjusting spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3 Rear window wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.1 Assembly overview - rear window wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.2 Removing and installing wiper blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.3 Removing and installing wiper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.4 Adjusting wiper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.5 Removing and installing rear window wiper motor V12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4 Rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.1 Assembly overview - rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.2 Removing and installing washer fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.3 Removing and installing rear window washer pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.4 Removing and installing spray jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.5 Adjusting spray jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5 Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.1 Assembly overview - headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.2 Removing and installing washer fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.3 Removing and installing headlight washer system pump V11 . . . . . . . . . . . . . . . . . . . . . . 109
5.4 Removing and installing pop-up cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.5 Removing and installing washer jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.6 Adjusting spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.7 Bleeding headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6 Washer fluid lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.1 Washer fluid line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.2 Repairing washer fluid lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
ii Contents
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
1 Headlights . . . . . . . . . . . . . . . . g. e.n.A.G.. V
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1.1 Assembly overview - headlight yV
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1.2 Removing and installing ris headlight . . . . . . . . . . . . . . . . . . . . . .nt.ee. . . . . . . . . . . . . . . . . . . . .
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1.3 Adjusting headlights uth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r a. . . . . . . . . . . . . . . . . . . 120
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1.4 Adjusting headlight installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.5 Removing and installing front turn signal bulb M5 / M7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
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1.6 Installing repair kit for headlight housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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1.7 Converting headlights from driving on right to driving on left . . . . . . . . . . . . . . . . . . . . . . . . 125
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1.8 Converting headlights from driving on left to driving on right . . . . . . . . . . . . . . . . . . . . . . . . 126
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1.9 Removing and installing headlight range control motor V48 / V49 . . . . . . . . . . . . . . . . . . 127
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1.10 Removing and installing headlight dipped beam bulb M29 / M31 . . . . . . . . . . . . . . . . . . . . 132
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1.11 Removing and installing headlight main beam bulb M30 / M32 . . . . . . . . . . . . . . . . . . . . 136
1.12 Removing and installing side light bulb M1 / M3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.13 Removing and installing daytime running light bulb L174 / L175 . . . . . . . . . . . . . . . . . . . . 142
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1.14 Removing and installing output module for headlight J667 / J668 . . . . . . . . . . . . . . . . . . 147
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1.15 Removing and installing output module 1 for LED headlight A27 / A31 . . . . . . . . . . . . . . 149
1.16 Removing and installing LED headlight fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
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1.17 Fine adjustment of LED modules - LED headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
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2 Fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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2.1 Assembly overview - fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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2.2 Removing and installing fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
thi
s
iva
2.3 Removing and installing fog light bulb L22 / L23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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rp
cum
2.4 Removing and installing static cornering light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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t.
2.5 Adjusting fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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3 Turn signal repeater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
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3.1 Removing and installing turn signal repeater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
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3.2 Removing and installing turn signal repeater bulb M18/M19 . . . . . . . . . . . . . . . . . . . . . .
Prote
158
AG.
4 Lights in sill panel moulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.1 Removing and installing entry light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.2 Removing and installing bulb for entry light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
5 Tail lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
5.1 Assembly overview - tail lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
5.2 Removing and installing bulb carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.3 Removing and installing tail light cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.4 Removing and installing tail light bulb M2 / M4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.5 Removing and installing rear fog light bulb L46 / L47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
5.6 Removing and installing brake light bulb M9 / M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
5.7 Removing and installing reversing light bulb M16 / M17 . . . . . . . . . . . . . . . . . . . . . . . . . . 180
5.8 Removing and installing turn signal bulb M6 / M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
6 High-level brake light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
6.1 Removing and installing high-level brake light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
6.2 Removing and installing high-level brake light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
7 Number plate light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
7.1 Removing and installing number plate light X4 / X5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
7.2 Removing and installing bulb for number plate light X4 / X5 . . . . . . . . . . . . . . . . . . . . . . . . 195
8 Steering column switch module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
8.1 Assembly overview - steering column switch module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
8.2 Removing and installing steering column electronics control unit J527 . . . . . . . . . . . . . . 198
8.3 Removing and installing steering column combination switch . . . . . . . . . . . . . . . . . . . . . . 199
8.4 Removing and installing steering column switch module . . . . . . . . . . . . . . . . . . . . . . . . . . 200
8.5 Removing and installing ignition/starter switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
8.6 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
8.7 Removing and installing steering lock housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
9 Parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Contents iii
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
9.1 Assembly overview – parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
9.2 Removing and installing parking aid control unit J446 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
9.3 Removing and installing front parking aid warning buzzer H22 . . . . . . . . . . . . . . . . . . . . 208
9.4 Removing and installing warning buzzer 2 for rear parking aid H31 . . . . . . . . . . . . . . . . . . 210
9.5 Adjusting volume and frequency of warning buzzer 2 for rear parking aid H31 . . . . . . . . 212
9.6 Removing and installing front parking aid senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
9.7 Removing and installing rear parking aid senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
10 Automatic headlight range control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
10.1 Removing and installing headlight range control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
11 Towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
11.1 Assembly overview - towing bracket socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
11.2 Trailer socket U10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
11.3 Removing and installing trailer socket U10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
11.4 Removing and installing trailer detector control unit J345 . . . . . . . . . . . . . . . . . . . . . . . . . . 219
96 - Lights, bulbs, switches - interior . . . . . . .wa.g.en.A.G.. V.ol.ks.w.ag.e.n A. G. d.oe. . . . . . . . . . . . . . . . . 220
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1 Lights . . . . . . . . . . . . . . . . . . . . . .d.by. V. o. . . . . . . . . . . . . . . . . . . . . . .o.t g. u.a. . . . . . . . . . . . . . . 220
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1.1 Overview of fitting locations - lights horis in dash panel . . . . . . . . . . . . . . . . . . .nt.ee. . . . . . . . . . . . 220
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1.2 Overview of fitting locations s-s alights in luggage compartment . . . . . . . . . . . . r.ac. . . . . . . . . 222
1.3 Overview of fitting locations - lights in roof trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
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1.4 Removing and installing glove compartment light W6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
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1.5 Replacing bulb for glove compartment light W6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
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1.6 Removing and installing front entry light W31 / W32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
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1.7 Removing and installing bulb for front entry light W31 / W32 . . . . . . . . . . . . . . . . . . . . . . 226
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ole,
1.8 Removing and installing rear entry light W33 / W34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
spec
urposes, in part or in wh
1.9 Removing and installing bulb for rear entry light W33 / W34 . . . . . . . . . . . . . . . . . . . . . . 228
t to the co
1.10 Removing and installing luggage compartment light W3 . . . . . . . . . . . . . . . . . . . . . . . . . . 229
1.11 Removing and installing bulb for luggage compartment light W3 . . . . . . . . . . . . . . . . . . . . 230
1.12 Removing and installing vanity mirror light W20 / W14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
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1.13 Removing and installing bulb for illuminated vanity mirror W20 / W14 . . . . . . . . . . . . . . . . 231
1.14 Removing and installing front interior light/reading light . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
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1.15 Removing and installing bulb for front interior light/reading light . . . . . . . . . . . . . . . . . . . . 234
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1.16 Removing and installing rear interior light/reading light . . . . . . . . . . . . . . . . . . . . . . . . . . . . f inform 237
mer
1.17 Removing and installing bulb for rear interior light/reading light . . . . . . . . . . . . . . . . . . . . . . 241
atio
om
2 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
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2.1 Overview of fitting locations - controls in dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
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2.2 Overview of fitting locations - controls in front doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
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2.3 Overview of fitting locations - controls in luggage compartment . . . . . . . . . . . . . . . . . . . . 249
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2.4 Overview of fitting locations - controls in roof trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
t. Cop py
rig 250
2.5 Removing and installing rotary light switch EX1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
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2.6 Removing and installing regulator for switch and instrument illumination E20 . . . . . . . . . . 251
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2.7 Removing and installing headlight range control regulator E102 . . . . . . . . . . . . . . . . . . . . 252
AG.
2.8 Removing and installing Start/Stop operation button E693 . . . . . . . . . . . . . . . . . . . . . . . . 252
2.9 Removing and installing TCS and ESP button E256 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
2.10 Removing and installing parking aid button E266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2.11 Removing and installing front passenger side airbag deactivated warning lamp K145 . . 253
2.12 Removing and installing heated rear window switch E15 . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2.13 Removing and installing tyre pressure monitor display button E492 . . . . . . . . . . . . . . . . . . 253
2.14 Removing and installing heated windscreen button E627 . . . . . . . . . . . . . . . . . . . . . . . . . . 254
2.15 Removing and installing rear differential lock switch E121 . . . . . . . . . . . . . . . . . . . . . . . . 254
2.16 Removing and installing hill descent control button E618 . . . . . . . . . . . . . . . . . . . . . . . . . . 255
2.17 Removing and installing sliding door button E442 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
2.18 Removing and installing button to deactivate sliding door E443 . . . . . . . . . . . . . . . . . . . . 255
2.19 Removing and installing interior light switch (taxi) E115 . . . . . . . . . . . . . . . . . . . . . . . . . . 255
2.20 Removing and installing taxi sign switch E138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
iv Contents
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
2.21 Removing and installing buttons in centre of dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . 256
2.22 Removing and installing hazard warning light switch EX3 . . . . . . . . . . . . . . . . . . . . . . . . 257
2.23 Removing and installing buttons for seat heating E653 / E654 . . . . . . . . . . . . . . . . . . . . . . 257
2.24 Removing and installing glove compartment light switch E26 . . . . . . . . . . . . . . . . . . . . . . 257
2.25 Removing and installing mirror adjustment switch E43 / E168 . . . . . . . . . . . . . . . . . . . . . . 258
2.26 Removing and installing operating unit for window regulator in driver door E512 . . . . . . . . 259
2.27 Removing and installing window regulator switch in front passenger door E107 . . . . . . . . 260
2.28 Removing and installing driver side interior locking button for central locking system E308
........................................................................ 260
2.29 Removing and installing rear lid remote release button E233 . . . . . . . . . . . . . . . . . . . . . . 262
2.30 Removing and installing door contact switch F2 / F3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
2.31 Removing and installing rear door contact switches F10 / F11 . . . . . . . . . . . . . . . . . . . . . . 262
2.32 Removing and installing release button for rear lid lock cylinder F248 . . . . . . . . . . . . . . . . 264
2.33 Removing and installing rear lid closure button E574 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.34 Removing and installing rear lid warning buzzer H32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.35 Removing and installing rear lid contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
2.36 Removing and installing vanity mirror contact switch F147 / F148 . . . . . . . . . . . . . . . . . . 265
AG. Volkswagen AG d
2.37 Removing lksw
agenand installing slidingoes sunroof adjustment regulator E139 . . . . . . . . . . . . . . . . . .
not
265
o
2.38 edRemoving
by V
and installing front interior gu light/reading light . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ara 267
is nte
2.39
thor Removing and installing rear interior light/reading
eo light . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
u ra
ss2.40
a Removing and installing front reading light button
c E633 / E634 and button for central
deactivation of interior light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
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2.41 Controls in interior, Business . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
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3 Anti-theft alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
ab
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ility
3.1 Assembly overview - interior monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
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, is n
3.2 Removing and installing alarm horn H12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
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hole
3.3 Removing and installing anti-theft and tilt system control unit . . . . . . . . . . . . . . . . . . . . . . 274
spec
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3.4 Removing and installing interior monitor send and receive module 2 G305 with three
t to the co
ultrasonic sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3.5 Removing and installing deactivation button for vehicle inclination sender . . . . . . . . . . . . 278
rrectness of i
4 Immobiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
4.1 General description - immobiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
l purpos
4.2 Removing and installing immobiliser control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
4.3 Adapting immobiliser control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
nform
ercia
4.4 Removing and installing immobiliser reader coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
m
5 Lane change assist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
com
tion in
5.1 Assembly overview - lane change assist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
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5.2 Removing and installing lane change assist warning lamp in exterior mirror K233 / K234
s
iva
do
........................................................................ 282
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5.3 Removing and installing lane change assist control unit J769 / J770 . . . . . . . . . . . . . . . . 282
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5.4 t. CCalibrating lane change assist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
op py
rig 283
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6 Front camera for assist systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
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7 Cigarette lighter, socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote
cted AG.
agen
292
7.1 Overview of fitting locations - DC/AC converter with socket, 12 V-230 V . . . . . . . . . . . . . . 292
7.2 Assembly overview - DC/AC converter with socket, 12 V-230 V . . . . . . . . . . . . . . . . . . . . 293
7.3 Assembly overview - cigarette lighter, 12 V socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
7.4 Removing and installing cigarette lighter U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
7.5 Removing and installing socket illumination bulb L42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
7.6 Removing and installing rear cigarette lighter illumination bulb L32 . . . . . . . . . . . . . . . . . . 294
7.7 Removing and installing electric socket U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
7.8 Removing and installing DC/AC converter with socket, 12 V-230 V U13 . . . . . . . . . . . . . . 295
7.9 Removing and installing 230 V socket insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
7.10 Removing and installing 230 V socket housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
7.11 Fuses for AC/DC converter with socket, 12 V-230 V U13 . . . . . . . . . . . . . . . . . . . . . . . . . . 300
8 Controls in interior, Business . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Contents v
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
8.1 Removing and installing seat adjustment switch unit, rotating seats, as of model year 2012,
Business . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
8.2 Removing and installing seat adjustment switch unit, double seat row, as of model year 2012,
Business . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
8.3 Removing and installing seat heating switch, double seat row, as of model year 2012,
Business . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
1 Relay carriers, fuse holders, electronics boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
1.1 Overview of fitting locations - relay carriers, fuse holders, E-boxes . . . . . . . . . . . . . . . . . . 304
1.2 Removing and installing electronics box on left side of engine compartment . . . . . . . . . . 305
1.3 Removing and installing coupling station in seat box at front on left . . . . . . . . . . . . . . . . . . 309
1.4 Removing and installing relay carrier and fuse holder in front seat boxes . . . . . . . . . . . . . . 310
1.5 Removing and installing relay carrier and fuse holder in centre console . . . . . . . . . . . . . . 311
1.6 Removing and installing coupling station electronics box . . . . . . . . . . . . . . . . . . . . . . . . . . 311
1.7 Removing and installing relay carrier and fuse holder in electronics box . . . . . . . . . . . . . . 311
2 Control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
2.1 Overview of fitting locations - control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
2.2 Removing and installing onboard supply control unit J519 . . . . . . . . . . . . . . . . . . . . . . . . 313
2.3 Removing and installing data bus diagnostic interface J533 . . . . . . . . . . . . . . . . . . . . . . . . 314
2.4 Removing and installing special vehicle control unit J608 . . . . . . . . . . . . . . . . . . . . . . . . 314
2.5 Coding special vehicle control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
2.6 Removing and installing rear lid power opening control unit J938 . . . . . . . . . . . . . . . . . . 316
3 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
3.1 Repairing electrical wiring harnesses and plug-in connections . . . . . . . . . . . . . . . . . . . . . . 317
4 Releasing and dismantling connector housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
5 Repairing aerial wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
6 Fibre optic cables . . . . . .. V. o.lk.s.w.ag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
AG en AG
agen do s
7 Vehicle diagnosis,
Vol
kswtesting and informationesystems not .............................. 321
by gu
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ed nte
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es, in part or in w
t to the co
rrectness of i
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vi Contents
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
00 – Technical data
1 Safety information
(VRL012840; Edition 04.2019)
⇒ “1.1 Safety precautions when working on vehicles with a start/
stop system”, page 1
⇒ “1.2 Safety precautions when using testing and measuring in‐
struments during a road test”, page 1
⇒ “1.3 Operation and safety notes for gas discharge lamps”, page
2
1.1 Safety precautions when working on ve‐
hicles with a start/stop system
Observe the following when working on a vehicle with a start/stop
system:
DANGER!
Injury hazard as a result of automatic engine agstart
en AGin vehicles
. Volkswagen AG
does
with start/stop system. olksw not
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ed
♦ If the start/stop system of a vehicle
ho
ris is activated, the engine nte
e
aut
can start automatically, if required. A message will appear or
ac
s
in the dash panel insert. s
ce
e
nl
pt
du
♦ When working on the vehicle, make sure that the start/stop
an
itte
y li
system is deactivated (switch off the ignition; switch the
erm
ab
ignition on again if necessary).
ility
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wit
, is n
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hole
1.2 Safety precautions when using testing spec
es, in part or in w
and measuring instruments during a t to the co
road test
rrectness of i
Observe the following if test and measuring equipment is required
during a road test:
l purpos
DANGER!
nform
mercia
Risk of accident due to distraction and inadequate securing of
at
om
io
test and measuring equipment.
n
c
in t
or
his
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Danger as a result of activation of front passenger airbag in
at
do
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event of an accident.
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• Operation of test and measuring equipment while driving
ng
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results in distraction. t. Cop py
rig
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• The risk of injuries increases significantly when test and pyri by
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measuring equipment is not secured.
lksw
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Prote AG.
♦ Always strap test and measuring equipment in place on
rear seat, and have a 2nd person operate them.
1. Safety information 1
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Electrical system - Edition 04.2019
1.3 Operation and safety notes for gas dis‐
charge lamps
Note
Never change bulbs if you are not familiar with the appropriate
procedures, safety precautions or tools.
WARNING
Danger to life due to high voltage.
♦ It is essential that the battery earth cable is disconnected
before any work on parts of the gas discharge headlight is
performed. The parts a marked with a yellow high voltage
symbol.
♦ Then switch dipped beam on and off again. This will elim‐
inate any possible residual voltage.
♦ Switch off ignition and all electrical consumers, andagwith‐
en AG. V
olkswagen AG
does
draw ignition key. Volksw not
g y ua
db ran
♦ The gas discharge lamp control unit must
or never be oper‐
ise tee
ated without a gas discharge lamp. auth or
ac
ss
♦ Due to the high voltage, the gas discharge lamp must only
ce
le
un
pt
be operated in the headlight housing. Voltages above
an
d
itte
28,000 V occur when igniting the gas discharge lamp.
y li
erm
ab
ility
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wit
is n
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ole,
WARNING
spec
urposes, in part or in wh
t to the co
Risk of injury due to burns, ultraviolet radiation, glare and ex‐
plosion.
♦ Due to high temperatures, the absorption of ultraviolet ra‐
diation and risk of glare, the gas discharge lamp must only rrectne
be operated in the headlight housing.
ss o
♦ Avoid looking directly into the light beam; otherwise vision
cial p
f in
may be impaired for a substantial time.
form
mer
♦ Gas discharge lamps are under high internal pressure and
atio
m
can explode while being changed.
o
n
c
i
or
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e
♦ Always wear eye protection and gloves when removing
t
sd
va
and installing gas discharge lamps!
i
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t.
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Cop py
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WARNING yri
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Risk of environmental pollution.
AG.
♦ Gas discharge lamps are classified as hazardous waste.
They contain metallic mercury (Hg) and traces of thallium.
♦ Gas discharge lamps must not be destroyed. Avoid con‐
tact with burst bulbs.
♦ Observe relevant disposal regulations.
♦ Only dispose of gas discharge lamps in containers inten‐
ded for this purpose at an authorised collection point.
2 Rep. gr.00 - Technical data
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Electrical system - Edition 04.2019
Caution
♦ Do not touch the bulb of the gas discharge lamp with bare
fingers. When the light bulb is switched on, the heat would
vaporise the oil of the finger prints which would then settle
on the reflector, impairing the brightness of the headlight.
Wear clean fabric gloves when inserting a gas discharge
lamp.
♦ A defective gas discharge lamp must always be renewed
with a new gas discharge lamp of the same type. The
designation appears on the base of the bulb or on the bulb
glass.
♦ Properly engage connectors during installation and the
connection is seated tightly.
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spec
urposes, in part or in wh
t to the co
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cial p
f inform
mer
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1. Safety information 3
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Electrical system - Edition 04.2019
2 Repair instructions
⇒ “2.1 Contact corrosion”, page 4
⇒ “2.2 Routing and attachment of lines”, page 4
2.1 Contact corrosion
. Volkswagen AG
a gen AG d
Contact corrosion can occur
Vol if unsuitable fasteners (bolts,
ksw
oes
not
gu
nuts,
washers, etc.) are used.
ed by ara
n is tee
or
For this reason,auonly
th connecting elements with a special surface
or
ac
coating have sbeen fitted.
s
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le
un
pt
In addition, rubber, plastic and adhesives are made of non-con‐
an
d
itte
ductive materials.
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erm
ab
ility
If there is any doubt about the suitability of parts, a general rule
ot p
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is to use new parts ⇒ Electronic parts catalogue .
is n
h re
ole,
Please note:
spec
urposes, in part or in wh
♦ Only use genuine replacement parts which are tested and
t to the co
compatible with aluminium.
♦ Only use Volkswagen Genuine Accessories.
rrectne
♦ Damage resulting from contact corrosion is not covered by the
warranty.
ss o
cial p
2.2 Routing and attachment of lines f inform
mer
♦ Mark lines prior to removal to prevent them from being inter‐
atio
m
changed and to ensure that they are fitted in their original
o
n
c
positions. This applies for fuel, hydraulic and vacuum lines as
or
n thi
e
well as lines for activated charcoal filter system and electrical
t
sd
va
wiring. Make sketches or take photographs if necessary.
i
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pr
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♦ To avoid damaging pipes and wires, ensure adequate clear‐
t.
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ance from all moving or hot components in the engine com‐ Cop py
t. rig
partment on account of the confined space. opyri
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♦ Any wiring fasteners which have been released during remov‐ Prote
cted agen
al must be of the same type and must be attached at the same
AG.
locations when installing to prevent any rattling or damage.
4 Rep. gr.00 - Technical data
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Electrical system - Edition 04.2019
3 Battery
⇒ “3.1 Battery - general notes”, page 5
⇒ “3.2 Types of battery”, page 5 AG. Volkswagen AG d
agen oes
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3.1 Battery - general notes d b ara
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Note nl
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All instructions and information about this chapter: ⇒ Electrical
erm
ab
ility
system; General information; Rep. gr. 27 ; Battery .
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3.2 Types of battery
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Note
rrectness of i
All instructions and information about this chapter: ⇒ Electrical
system; General information; Rep. gr. 27 ; Battery; Battery types .
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3. Battery 5
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Electrical system - Edition 04.2019
27 – Starter, current supply, CCS
1 Battery
⇒ “1.1 Assembly overview - battery”, page 6
⇒ “1.2 Checking battery”, page 7
⇒ “1.3 Charging battery”, page 7
⇒ “1.4 Disconnecting and connecting battery”, page 7
⇒ “1.5 Removing and installing battery”, page 11 AG. Volkswagen AG d
agen oes
olksw not
⇒ “1.6 Removing and installing battery partition”, page 15 d by
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⇒ “1.7 Removing and installing battery tray”, page 15 ut
ho eo
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⇒ “1.8 Removing and installing battery isolator”, page 16
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un
pt
an
⇒ “1.9 Removing and installing earth wire with battery monitor
d
itte
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control unit J367 ”, page 17
rm
ab
pe
ility
⇒ “1.10 Adapting battery monitor control unit J367 ”, page 18
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wit
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1.1 Assembly overview - battery
hole
spec
es, in part or in w
t to the co
1 - Battery
❑ Disconnecting and re‐
rrectness of i
connecting battery
⇒ page 8
l purpos
❑ Charge battery
⇒ page 7 .
nform
ercia
❑ After replacing battery,
m
adapt battery monitor
a
com
ti
control unit - J367-
on in
⇒ page 18
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❑ Removing and installing
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⇒ page 17
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2 - Nut
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❑ Nut for earth wire to
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❑ 20 Nm
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3 - Nut
❑ 6 Nm
4 - Earth wire battery terminal
clamp
❑ With integrated battery
monitor control unit -
J367-
❑ Disconnecting and re‐
connecting battery
⇒ page 8
5 - Electrical connector
6 - Positive wire battery termi‐
nal clamp
❑ Disconnecting and re‐
connecting battery
⇒ page 8
6 Rep. gr.27 - Starter, current supply, CCS
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
7 - Nut
❑ 6 Nm
8 - Bolt
❑ 23 Nm
9 - Clamping rail
10 - Hose for central gas venting system
❑ Hose for central gas venting system must be fitted on battery
❑ The hose for the central gas venting system must not be clamped off when installing. Otherwise, the
battery cannot vent properly. en AG. V
olkswagen AG
ag does
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y Vol gu
b ara
ed nte
ris
1.2 Checking battery tho eo
au ra
c
ss
Check battery ⇒ Electrical system, General information; Rep. gr.
ce
e
nl
pt
du
27 ; Checking battery .
an
itte
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erm
ab
1.3 Charging battery
ility
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, is n
Battery recharging or jump start on vehicles with start/stop sys‐
h re
tem:
hole
spec
es, in part or in w
When recharging or jump starting vehicles with start/stop system,
t to the co
note the following: first connect charging cable to battery positive
terminal then body earth. This ensures that the battery monitor
control unit - J367- is not bridged. Charging the battery directly on
rrectness of i
the negative terminal causes the battery monitoring control unit
to be bridged. The battery data is not collected by the battery
l purpos
monitoring control unit during the charging process. Then, the
values concerning the battery state and saved in the data bus
nform
ercia
diagnostic interface would not correspond to the values of the
charged battery.
m
at
om
io
Information on charging batteries is summarised in the Workshop
n
c
in t
r
Manual “Electrical system, General information”.
o
his
ate
do
riv
1.4 Disconnecting and connecting battery
p
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for
en
ng
⇒ “1.4.1 Disconnecting and connecting battery, earth wire on
t.
yi Co
op
negative battery terminal”, page 7
C py
t. rig
gh ht
yri by
⇒ “1.4.2 Disconnecting and connecting battery, battery A in en‐ cop Vo
by lksw
gine compartment”, page 8
cted agen
Prote AG.
⇒ “1.4.3 Connecting and disconnecting second battery A1 be‐
neath front left seat”, page 9
1.4.1 Disconnecting and connecting battery,
earth wire on negative battery terminal
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
1. Battery 7
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California
horis 2016 ➤ , Caravelle 2016 ➤ , Multivan t2016
ee ➤ , Transporter 20 ...
t or
Electrical
au system - Edition 04.2019 ac
ss
ce
le
un
Disconnecting
pt
an
d
itte
y li
– If fitted, disconnect negative battery terminal of second battery
rm
ab
pe
- A1- .
ility
ot
wit
, is n
– Loosen nut -1-.
h re
hole
spec
– Detach negative battery clamp -2-.
es, in part or in w
t to the co
– Disconnect electrical connector -3-.
Connecting
rrectness of i
Connect in reverse order of removal, noting the following:
l purpos
– Perform initialisation (activation) of window regulator ⇒ Main‐
tenance ; Booklet 10.3 .
nform
ercia
– Check time and adjust, if necessary.
m
a
com
t
– Read event memory ⇒ Maintenance ; Booklet 10.3 .
ion in
r
te o
– Perform zero compensation of steering angle sender ⇒ Vehi‐
thi
s
iva
cle diagnostic tester.
do
r
rp
cum
fo
Specified torques
en
ng
t.
yi Co
op
♦ ⇒ “1.1 Assembly overview - battery”, page 6 C py
t. rig
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pyri by
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co
1.4.2 Disconnecting and connecting battery,
by lksw
cted agen
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battery - A- in engine compartment
WARNING
Danger of injury! Observe warning instructions and safety reg‐
ulations ⇒ page 5 .
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1410-
Disconnecting
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
8 Rep. gr.27 - Starter, current supply, CCS
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Electrical system - Edition 04.2019
– First loosen securing nut of battery earth cable a few turns and
pull battery terminal clamp -1- of earth cable off battery termi‐
nal.
– Then loosen securing nut of battery positive cable a few turns
and pull battery terminal clamp -2- of positive cable off battery
terminal.
Connecting
Observe the following when connecting the battery - A- :
– Release and separate electrical connector -2- on battery mon‐
itor control unit - J367- -3-.
– Fit battery terminal clamp of earth cable to negative battery
terminal by hand.
Note
To prevent noises, push the positive terminal
wage
cable
n AG. Volksagainst
wagen AGthe
does
battery body when tightening the terminal
yV
olks
clamp. not
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ed nte
oris e
– Tighten nut -1-. au
th or
ac
ss
– Reattach electrical connector -2- to battery monitor control unit
ce
e
nl
pt
- J367- -3-.
du
an
itte
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erm
– Connect battery terminal clamp of positive wire to battery pos‐
ab
ility
itive terminal and tighten nut.
ot p
wit
, is n
– Switch on ignition.
h re
hole
spec
– Check time and adjust, if necessary.
es, in part or in w
t to the co
– Completely open windows, and then completely close them.
– Check convenience mode of the window regulators.
rrectness of i
– Read event memory ⇒ Vehicle diagnostic tester.
l purpos
– Steering angle sender - perform zero compensation ⇒ Vehicle
diagnostic tester.
nf
ercia
Specified torques
rm
m
atio
m
♦ ⇒ “1.1 Assembly overview - battery”, page 6
o
n in
or c
thi
te
sd
1.4.3 Connecting and disconnecting second
iva
o
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rp
cu
battery - A1- beneath front left seat
o
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f
en
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t.
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Cop py
t. rig
WARNING
gh ht
pyri by
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co lksw
by
cted agen
Danger of injury! Observe warning instructions and safety reg‐
Prote AG.
ulations ⇒ page 5 .
Special tools and workshop equipment required
1. Battery 9
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Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1410-
Disconnecting
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Move left front seat to foremost position.
– Disconnect negative battery terminal of battery - A- in engine
compartment ⇒ page 8 .
– Pull trim -1- off seat box. n AG. Volkswagen AG do
lkswage es n
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– Remove battery cover -3- from second battery - A1- . ised b ua
ran
or tee
h
– First loosen securing nut of battery earth cable a fews aturns
ut
and or
ac
pull battery terminal clamp -2- of earth cable off battery termi‐
s
ce
le
nal.
un
pt
an
d
itte
y li
– Then loosen securing nut of battery positive cable a few turns
rm
ab
and pull battery terminal clamp -4- of positive cable off battery
pe
ility
terminal.
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wit
, is n
h re
Connecting
hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia
– First fit terminal clamp of positive wire -4- on battery positive
m
a
terminal and tighten securing nut.
com
tion in
– Then fit battery negative terminal clamp -2- on negative ter‐
r
te o
thi
minal of battery and tighten securing nut.
s
iva
do
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rp
– Install battery cover -3- and trim -1-.
um
fo
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ng
t.
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– Connect negative battery terminal of battery - A- in engine
Co
Cop py
compartment ⇒ page 8 .
t. rig
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pyri by
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Specified torques
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♦ ⇒ “1.1 Assembly overview - battery”, page 6
10 Rep. gr.27 - Starter, current supply, CCS
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California 2016 ➤ , Caravelle
tho 2016 ➤ , Multivan 2016 ➤ , Transporter tee
or 20 ...
u
ss
a
Electrical system - Edition 04.2019ac
ce
le
un
pt
1.5 Removing and installing battery
an
d
itte
y li
erm
ab
⇒ “1.5.1 Removing and installing battery A in engine compart‐
ility
ot p
ment”, page 11
wit
is n
h re
ole,
⇒ “1.5.2 Removing and installing second battery A1 beneath front
spec
left seat”, page 13
urposes, in part or in wh
t to the co
1.5.1 Removing and installing battery - A- in
engine compartment
rrectne
WARNING
ss o
cial p
f i
Observe safety precautions when working on vehicles with
nform
start/stop system ⇒ page 1 .
mer
atio
om
n
c
i
or
n thi
Renewing battery on vehicles with start/stop system
te
sd
iva
o
pr
cum
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fo
en
ng
Note
t.
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Cop py
t. rig
♦ Due to higher demands on the deep-cycle resistance, a spe‐
gh ht
pyri by
cial battery is used in vehicles equipped with a start/stop
co Vo
by lksw
cted
system.
agen
Prote AG.
♦ When renewing the battery, note the correct part designation
⇒ ETKA .
♦ Batteries intended for use in vehicles with a start/stop system
are marked “AGM” (Absorbent Glass Mat) or “EFB” (En‐
hanced Flooded Battery).
♦ If the battery is renewed, the battery monitor control unit -
J367- must be adapted by means of a battery parametrisation
⇒ page 18 .
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1410-
WARNING
Always make sure to comply with the warning notices and
safety regulations when working on the battery ⇒ Electrical
system, General information; Rep. gr. 27 ; Battery .
Removing
– Disconnect battery - A- ⇒ page 7 .
– If fitted, pull hose for central venting off battery.
1. Battery 11
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Electrical system - Edition 04.2019
– Unscrew bolt -arrow- and remove together with clamp plate.
Note
♦ Do not allow the loosened clamp plate with securing bolt to fall
into the body aperture in front of the battery.
♦ To retrieve a clamp plate that has fallen into the body, the
headlight must be removed.
– Open heat guard and remove from battery.
– Fold up battery handles -arrows-.
– Grab battery by handles and lift it out upwards.
Installing
Caution
A loosely installed battery creates the following dangers:
♦ Shortened service life caused by vibration damage (dan‐
ger of explosion)
♦ The plates in the battery cells will be damaged if the bat‐
tery is not secured correctly. agen
AG. Volkswagen AG d
oes
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♦ Damage to battery casing by clamping
db
yV
o
bracket (possible gu
ara
leakage of acid with high consequential
orise costs). nte
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th
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♦ Poor crash safety. ss c
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pt
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Installation is carried out in the reverse order. When installing ob‐
erm
ab
serve the following:
ility
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, is n
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– Bring clamp plate into position and tighten bolt -arrow-.
hole
spec
es, in part or in w
t to the co
Note
♦ If fitted, connect the hose for central venting to the battery.
rrectness of i
♦ The hose for central venting must not be pinched when instal‐
l purpos
ling. Otherwise the battery won't be able to vent freely.
nform
ercia
– Check battery is firmly seated after installation.
m
at
– Connect battery ⇒ page 7 .
om
ion
c
in t
r
After installing a new starter battery or a new battery monitor con‐
o
his
e
trol unit - J367- , the battery monitor control unit - J367- must be
at
do
riv
adapted ⇒ page 18 .
p
cum
for
en
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Specified torques
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♦ ⇒ “1.1 Assembly overview - battery”, page 6
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12 Rep. gr.27 - Starter, current supply, CCS
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
1.5.2 Removing and installing second battery
- A1- beneath front left seat
WARNING
Danger of injury! Observe warning instructions and safety reg‐
ulations ⇒ page 5 .
An absorbent glass mat battery is also installed beneath the front
left seat on some vehicles, depending on the equipment level.
The electrolyte of the VRLA battery is not free and therefore can‐
not leak out, is cycle resistant and is absolutely maintenance free.
VRLA batteries are more resistant to climatic influences and vi‐
brations than are common lead acid batteries. Further, VRLA
battery will not develop leaks or be damaged by swinging or tip‐
ping.
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1410-
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WARNING
rrectness of i
Always make sure to comply with the warning notices and
l purpos
safety regulations when working on the battery ⇒ Electrical
system, General information; Rep. gr. 27 ; Battery . nform
mercia
Removing
com
tion in
– Remove front left seat ⇒ General body repairs, interior; Rep.
r
te o
thi
gr. 72 ; Front seats; Removing and installing front seat .
s
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– Disconnect battery - A- on left in engine compartment
fo
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⇒ page 7 .
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– Disconnect second battery under left front seat ⇒ page 9 .
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– If fitted, pull hose for central venting off battery.
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1. Battery 13
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Electrical system - Edition 04.2019
– Unscrew bolt -arrow- and remove clamp plate.
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– Fold up battery handles -arrows-.
hole
spec
– Hold battery by handles and lift it out from bracket under seat.
es, in part or in w
t to the co
Installing
rrectness of i
Caution
l purpos
A loosely installed battery creates the following dangers:
nform
♦ Shortened service life caused by vibration damage (dan‐
ercia
ger of explosion)
m
at
om
io
♦ The plates in the battery cells will be damaged if the bat‐
n
c
in t
tery is not secured correctly.
or
his
ate
do
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♦ Damage to battery casing by clamping bracket (possible
p
cum
leakage of acid with high consequential costs).
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♦ Poor crash safety.
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– Bring clamp plate into position and tighten bolt -arrow-.
AG.
Note
♦ If fitted, connect the hose for central venting to the battery.
♦ The hose for central venting must not be pinched when instal‐
ling. Otherwise the battery won't be able to vent freely.
– After installing second battery - A1- , ensure it is firmly seated.
– Connect second battery under left front seat ⇒ page 9 .
– Install front seat ⇒ General body repairs, interior; Rep. gr. 72 ;
Front seats; Removing and installing front seat .
– Connect battery - A- on left in engine compartment
⇒ page 7 .
Specified torques
♦ ⇒ “1.1 Assembly overview - battery”, page 6
14 Rep. gr.27 - Starter, current supply, CCS
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e nte ➤ , Transporter 20 ...
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- Edition 04.2019
ss
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1.6 Removing and installing battery partition
un
pt
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Note
ot
wit
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hole
The battery partition has been discontinued for vehicles as of
spec
03.2018 in conjunction with a 68Ah absorbent glass mat battery
es, in part or in w
t to the co
or a 70Ah EFB+ battery.
Special tools and workshop equipment required
rrectness of i
♦ Torque wrench - V.A.G 1410-
l purpos
nform
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Removing
– Unscrew bolt -arrow- and remove upper part -1- of battery
partition.
– Pull out front part of battery partition -1- upwards.
– Unscrew bolt -arrow- and remove middle part of battery parti‐
tion -2- upwards.
– If rear part of battery partition is also to be removed, remove
battery ⇒ page 11 , unscrew securing bolt then unhook battery
partition from battery tray and remove.
Installing
Install in the reverse order of removal. When doing this, note the
following:
Specified torques
Component Specified torque
Bolt securing middle battery partition 20 Nm
to battery tray
Bolt securing upper battery partition 1.5 Nm
to radiator grille cover
1.7 Removing and installing battery tray
Special tools and workshop equipment required
1. Battery 15
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Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1410-
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Removing
– Remove battery - A- in engine compartment ⇒ page 11 .
rrectness of i
– Remove battery partition ⇒ page 15 .
l purpos
– Unscrew bolts -arrows- and remove battery tray.
Installing
nf
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or
Install in the reverse order of removal. When doing this, note the
m
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atio
following:
om
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Specified torques
thi
te
sd
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Component Specified torque
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Battery tray bolts 8 Nm
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1.8 Removing and installing battery isolator
⇒ “1.8.1 Checking battery isolation relay J7 ”, page 16
⇒ “1.8.2 Removing and installing battery isolation relay J7 ”, page
16
1.8.1 Checking battery isolation relay - J7-
– Connect vehicle diagnostic tester .
– Check battery isolation relay - J7- ⇒ Vehicle diagnostic tester.
1.8.2 Removing and installing battery isola‐
tion relay - J7-
The battery isolation relay - J7- and associated battery isolation
relay fuse - S171- can be found on relay carrier in the seat box
beneath the front left seat ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
Removing
– First disconnect battery - A- in engine compartment
⇒ page 8 .
– Then disconnect second battery - A1- beneath front left seat
⇒ page 9 .
16 Rep. gr.27 - Starter, current supply, CCS
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Pull battery isolation relay - J7- -1- or battery isolation relay
fuse - S171- -2- out of relay carrier.
Installing
– Insert battery isolation relay - J7- -1- and battery isolation relay
fuse - S171- -2- into intended location.
– First connect second battery - A1- beneath front left seat
⇒ page 9 .
– Then connect battery - A- in engine compartment ⇒ page 8 .
1.9 Removing and installing earth wire with
battery monitor control unit - J367-
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1410-
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Removing horis nte
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aut ra
– Separate electrical connector
ss -4- on battery monitor control c
unit - J367- -1-.
ce
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nl
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an
itte
– Loosen securing nut -3- of battery earth cable a few turns and
y li
erm
ab
pull battery terminal clamp -2- of earth cable off battery termi‐
ility
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nal.
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Unscrew securing bolts -1- of coolant expansion tank and
push tank with hoses connected to one side.
nf
ercia
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1. Battery 17
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California 2016 ➤ , Caravelle
auth 2016 ➤ , Multivan 2016 ➤ , Transportere o20 r a ...
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Electrical system - Edition 04.2019 ss
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– Unscrew securing nut -6- from weld stud and remove earth
itte
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cable -5- with battery monitor control unit - J367- -1-.
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Installing
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Install in the reverse order of removal. When doing this, note the
hole
spec
following:
es, in part or in w
t to the co
Specified torques
♦ ⇒ “1.1 Assembly overview - battery”, page 6
rrectness of i
l purpos
nform
ercia
1.10 Adapting battery monitor control unit -
m
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com
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J367-
ion in
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After the installation of a new starter battery or a new battery
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monitor control unit - J367- , the battery monitor control unit -
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cum
J367- must be adapted.
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– Connect vehicle diagnostic tester ⇒ page 321 . t. Cop py
rig
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– Adapt battery monitor control unit - J367- ⇒ Vehicle diagnostic pyri by
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tester.
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18 Rep. gr.27 - Starter, current supply, CCS
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
2 Alternator
⇒ “2.1 Assembly overview - alternator”, page 19
⇒ “2.2 Removing and installing alternator”, page 20
⇒ “2.3 Checking alternator”, page 23
⇒ “2.4 Checking poly V-belt”, page 23
⇒ “2.5 Removing and installing poly V-belt pulley”, page 24
⇒ “2.6 Removing and installing voltage regulator”, page 29
2.1 Assembly overview - alternator
⇒ “2.1.1 Assembly overview - alternator without sliding bushes”,
page 19
⇒ “2.1.2 Assembly overview - alternator with sliding bushes”,
page 20
2.1.1 Assembly overview - alternator without sliding bushes
1 - Alternator - C-
❑ Removing and installing
⇒ page 20
❑ Checking ⇒ page 23
❑ Removing and installing wage
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❑ Removing aut and installing
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voltagessregulator - C1-
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⇒ page 29
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2 - Electrical connector
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❑ Terminal 61
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3 - Battery positive wire
h re
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❑ Terminal 30/B+
spec
es, in part or in w
4 - Nut
t to the co
❑ Battery positive cable to
alternator
rrectness of i
❑ 15 Nm
l purpos
5 - Cover
6 - Alternator bolts
nf
ercia
or
❑ Insert upper securing
m
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atio
bolts in alternator before
om
bringing alternator into
n in
or c
position on cylinder
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block.
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❑ 23 Nm
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2. Alternator 19
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Electrical system - Edition 04.2019
2.1.2 Assembly overview - alternator with sliding bushes
1 - Alternator - C-
❑ Removing and installing
⇒ page 20 agen
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❑ Checking ⇒ page 23 d by
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❑ Removing and installing horis
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poly V-belt pulley aut ra
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⇒ page 24 s
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❑ Removing and installing
an
d
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voltage regulator - C1-
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⇒ page 29
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2 - Bolt
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❑ Qty. 2
hole
spec
❑ 20 Nm
es, in part or in w
t to the co
3 - Sliding bush
❑ Qty. 2
rrectness of i
❑ If a bush is stiff, its
clamping force will be in‐
l purpos
sufficient even though it
has been tightened to
nform
ercia
the correct torque. Free
off sliding bushes if nec‐
m
a
essary.
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4 - Electrical connector
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❑ DF cable
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5 - Cover
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6 - Nut
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7 - Terminal 30/B+
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8 - Nut
❑ Depending on equip‐
ment
❑ 3.2 Nm
9 - Clamp
❑ Depending on equipment
10 - Threaded pin
❑ Depending on equipment
❑ 3.2 Nm
2.2 Removing and installing alternator
⇒ “2.2.1 Removing and installing alternator, vehicles with TDI en‐
gine”, page 20
⇒ “2.2.2 Removing and installing alternator, vehicles with TSI en‐
gine”, page 22
2.2.1 Removing and installing alternator, ve‐
hicles with TDI engine
Special tools and workshop equipment required
20 Rep. gr.27 - Starter, current supply, CCS
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1331-
Removing
– Disconnect batteries ⇒ page 7 .
– Move lock carrier to service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier; Moving to service position .
– Remove poly V-belt ⇒ Rep. gr. 13 ; Cylinder block, pulley end;
Removing and installing poly V-belt .
– Release and disconnect connector of DF cable -1-.
– Lever off deflector cap -2-.
– Unscrew securing nut and detach the B+ wire under it from the
connecting thread of the alternator.
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– Undo and remove the two bolts -arrows-horis
securing the alterna‐ nte
eo
tor. aut ra
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un
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an
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Note
itte
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ility
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♦ If the alternator - C- is stuck in its bracket, screw in bolts
wit
is n
-arrows- again except for the last 2 turns.
h re
ole,
♦ Carefully hit bolt heads with flat side of hammer to release
spec
urposes, in part or in wh
sliding bushes of alternator mounting.
t to the co
– Remove alternator by taking it upwards out of the vehicle.
rrectne
Installing
Install in the reverse order of removal, observing the following:
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
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t.
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Prote AG.
2. Alternator 21
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Electrical system - Edition 04.2019
– To facilitate positioning of alternator - C- , drive back bushes
-A- of alternator mounting about 4 mm in direction of arrow.
– Start engine and check that belt runs properly after completing
work.
Specified torques
♦ ⇒ “2.1.2 Assembly overview - alternator with sliding bushes”,
page 20
2.2.2 Removing and installing alternator, ve‐
hicles with TSI engine
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
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Removing au ac
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– Disconnect batteries ⇒ page 7 .
un
pt
an
d
itte
– Remove poly V-belt ⇒ Rep. gr. 13 ; Cylinder block, pulley end;
y li
rm
ab
Removing and installing poly V-belt .
pe
ility
ot
wit
– Remove oil pressure switch ⇒ Rep. gr. 17 ; Oil filter/oil pres‐
, is n
h re
sure switch; Removing and installing oil pressure switch F22 .
hole
spec
– Detach connecting hose from pressure pipe ⇒ Rep. gr. 21 ;
es, in part or in w
t to the co
Charge air system; Assembly overview - charge air system .
– Remove air filter housing ⇒ Rep. gr. 24 ; Air filter; Removing
and installing air filter housing .
rrectness of i
l purpos
Note
nform
ercia
♦ The hoses attached to power steering vane pump do not have
m
to be detached.
a
com
tion in
♦ When doing this, the hoses on the vane pump must not be
r
te o
thi
kinked or stretched.
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22 Rep. gr.27 - Starter, current supply, CCS
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ho California 2016 ➤ , Caravelle 2016 ➤ee, oMultivan
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2016 ➤ , Transporter 20 ...
a
ss Electrical
c system - Edition 04.2019
ce
le
un
pt
– Disconnect electrical connector -1-.
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
– Remove protective cap -1-.
mer
atio
– Unscrew nut of wiring connection terminal 30.
om
n
c
i
or
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te
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Prote AG.
– Unscrew bolts -1-.
– Unscrew bolts -1-.
– Remove alternator upwards.
Installing
Install in the reverse order of removal, observing the following:
– Start engine and check that belt runs properly after completing
work.
– Check engine oil level ⇒ Maintenance ; Booklet 20.1 .
Specified torques
♦ ⇒ “2.1.1 Assembly overview - alternator without sliding bush‐
es”, page 19
2.3 Checking alternator
– Check alternator - C- ⇒ Vehicle diagnostic tester.
2.4 Checking poly V-belt
– Use a socket spanner to turn engine at vibration damper on
pulley.
2. Alternator 23
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Electrical system - Edition 04.2019
– Check poly V-belt for:
♦ Sub-surface cracks (cracks, core ruptures, cross sectional
breaks)
♦ Layer separation (top layer, cord strands)
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♦ Frayed cord strands orise nte
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♦ Flank wear (material wear, frayedssflanks,
a
flank brittleness - c
glassy flanks-, surface cracks)
ce
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♦ Traces of oil and grease
itte
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ility
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Caution
wit
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hole
In order to avoid failures and malfunctions, the poly V-belt must
spec
es, in part or in w
be replaced if it is damaged.
t to the co
2.5 Removing and installing poly V-belt pul‐
rrectness of i
ley
l purpos
⇒ “2.5.1 Removing and installing poly V-belt pulley without free‐
wheel”, page 24
nf
ercia
orm
⇒ “2.5.2 Removing and installing poly V-belt pulley with free‐
m
atio
m
wheel, manufacturer: Bosch”, page 25
o
n in
or c
thi
⇒ “2.5.3 Removing and installing poly V-belt pulley with free‐
te
sd
a
wheel, manufacturer: Valeo”, page 27
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2.5.1 Removing and installing poly V-belt pul‐
f
en
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t.
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ley without freewheel
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Special tools and workshop equipment required
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♦ Socket insert - 3310-
♦ Torque wrench - V.A.G 1332-
24 Rep. gr.27 - Starter, current supply, CCS
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
Removing
– Remove alternator - C- ⇒ page 20 .
– Clamp alternator - C- in vice at mounting points.
– Unscrew securing nut of poly V-belt pulley from alternator
shaft using socket - 3310- .
Volkswagen AG
– Remove poly V-belt pulley from alternator
swa
gen Ashaft.
G. does
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Installing by ara
ed nte
oris eo
h
Install in the reverse order aof
ut removal, observing the following: ra
c
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Specified torques
es, in part or in w
t to the co
Component Specified torque
Securing nut for poly V-belt pulley 65 Nm
rrectness of i
l purpos
2.5.2 Removing and installing poly V-belt pul‐
nf
ercia
ley with freewheel, manufacturer: Bosch
orm
m
atio
m
Special tools and workshop equipment required
o
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thi
♦ Multipoint adapter - 3400-
te
sd
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♦ Torque wrench - V.A.G 1332-
Removing
– Remove alternator - C- ⇒ page 20 .
– Clamp alternator - C- in vice at mounting points.
2. Alternator 25
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Electrical system - Edition 04.2019
– Lever off poly V-belt pulley cap.
– Insert adapter - 3400- into poly V-belt pulley using 17 mm ring
spanner.
– Insert M10 multipoint bit -1- into alternator shaft.
– Counterhold alternator shaft whilst releasing poly V-belt pulley
by turning it anti-clockwise with ring spanner.
– Hold poly V-belt pulley stationary by hand.
– Turn alternator shaft until poly V-belt pulley can be removed.
Installing
Install in the reverse order of removal, observing the following:
– Screw poly V-belt pulley by hand onto alternator shaft as far
as stop.
To install poly V-belt pulley, the torque wrench - V.A.G 1332-
needs to be set up as follows:
– Release socket drive -1- and pull off grip -2-.
– Turn grip -2- 180° and reinsert socket -1-.
– Set turning direction of torque wrench - V.A.G 1332- to anti-
clockwise at socket drive.
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– Insert M10 multipoint bit -1- into alternator shaft.
ility
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wit
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– Counterhold adapter - 3400- using 17 mm ring spanner.
h re
hole
spec
– Tighten poly V-belt pulley by turning alternator shaft anti-
es, in part or in w
clockwise using torque wrench - V.A.G 1332- .
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Securing nut for poly V-belt pulley 80 Nm
26 Rep. gr.27 - Starter, current supply, CCS
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
2.5.3 Removing and installing poly V-belt pul‐
ley with freewheel, manufacturer: Valeo
Special tools and workshop equipment required
♦ Multipoint adapter - 3400-
♦ Torque wrench - V.A.G 1332-
♦ TORX driver bit - V.A.G 1603/1-
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2. Alternator
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Insert adapter - 3400- into poly V-belt pulley using 17 mm ring
spanner.
– Insert TORX key - V.A.G 1603/1- into alternator shaft.
– Counterhold alternator shaft whilst releasing poly V-belt pulley
by turning it anti-clockwise with ring spanner.
– Hold poly V-belt pulley stationary by hand.
– Turn alternator shaft until poly V-belt pulley can be removed.
Installing
Install in the reverse order of removal, observing the following:
– Screw poly V-belt pulley by hand onto alternator shaft as far
as stop.
To install poly V-belt pulley, the torque wrench - V.A.G 1332-
needs to be set up as follows:
– Release socket drive -1- and pull off grip -2-.
– Turn grip -2- 180° and reinsert socket -1-.
– Set turning direction of torque wrench - V.A.G 1332- to anti-
clockwise at socket drive.
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28 Rep. gr.27 - Starter, current supply, CCS
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
2.6 Removing and installing voltage regula‐
tor
⇒ “2.6.1 Removing and installing voltage regulator C1 , manu‐
facturer: Bosch”, page 29
⇒ “2.6.2 Removing and installing voltage regulator C1 , Valeo”,
page 30
2.6.1 Removing and installing
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Removing
– Remove alternator - C- ⇒ page 20 .
– Using offset screwdriver for slotted-head screws - VAS 6416- ,
carefully lever off protective cap -1- at fasteners -arrows-.
2. Alternator 29
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016
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– Remove bolts -arrows- for voltage regulator
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– Remove voltage regulator - C1- from alternator - C- .
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Removing
– Remove alternator - C- ⇒ page 20 .
– Carefully lever protective cap -1- off alternator - C- .
30 Rep. gr.27 - Starter, current supply, CCS
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
n AG. Volkswagen AG do
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Specified torques
Component Specified torque
Securing bolts of voltage regulator - C1- 4 Nm
2. Alternator 31
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Electrical system - Edition 04.2019
3 Starter motor
⇒ “3.1 Assembly overview – starter”, page 32
⇒ “3.2 Checking starter”, page 33
⇒ “3.3 Removing and installing starter”, page 33
3.1 Assembly overview – starter
⇒ “3.1.1 Assembly overview - starter, vehicles with manual gear‐
box MQ250, MQ500”, page 32
⇒ “3.1.2 Assembly overview - starter, vehicles with dual clutch
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11 - Bracket
❑ For wiring harness
❑ Depending on equip‐
ment
32 Rep. gr.27 - Starter, current supply, CCS
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
AG. Volkswagen AG d
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❑ Depending on equip‐
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3.2 Checking starter
Check the starter - B- using the ⇒ Vehicle diagnostic tester.
3.3 Removing and installing starter
⇒ “3.3.1 Removing and installing starter, vehicles with manual
gearbox MQ250, MQ500”, page 33
⇒ “3.3.2 Removing and installing starter, vehicles with 4-cyl. in‐
jection engine and dual clutch gearbox DQ500”, page 35
⇒ “3.3.3 Removing and installing starter, vehicles with 4-cyl. die‐
sel engine and dual clutch gearbox DQ500”, page 37
3.3.1 Removing and installing starter, vehi‐
cles with manual gearbox MQ250,
MQ500
Special tools and workshop equipment required
3. Starter motor 33
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Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1331-
♦ Torque wrench - V.A.G 1332-
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Removing
– Disconnect batteries ⇒ page 7 . t to the co
– Remove noise insulation ⇒ General body repairs, exterior;
rrectness of i
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
l purpos
sulation .
– Release connector -1- and disconnect.
nform
ercia
– Press off cap -2-.
m
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– Unscrew securing nut -3- and remove terminal 30/B+.
on
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34 Rep. gr.27 - Starter, current supply, CCS
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– If fitted, unscrew nut -1- from upper bolt of starter - B- .
– If fitted, remove earth cable -2-.
– If fitted, unscrew nut -1- from lower bolt of starter - B- .
– If fitted, remove earth cable -2-.
– Unscrew nut -4- and remove retainer -1- with wiring harness
attached.
– Unscrew securing bolts -2- and -5- from starter - B- -3-.
– Remove starter - B- -3- downwards.
Installing
Install in the reverse order of removal, observing the following:
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3.3.2 Removing and installing starter, vehi‐
cles with 4-cyl. injection engine and dual
rrectness of i
clutch gearbox DQ500
l purpos
Special tools and workshop equipment required
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tion in
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3. Starter motor
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♦ Torque wrench - V.A.G 1331- ss
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Removing
– Disconnect battery ⇒ page 7 .
– Release and disconnect electrical connector -1-.
– Unclip wiring harness -3- from coolant expansion tank -2-.
– Remove securing bolts -4-.
– Lay coolant expansion tank -2- to one side with hoses still
connected.
Note
♦ To gain better access to the starter, the gearbox breather hose
may have to be unclipped and the retainer for the charge pres‐
sure sender may have to be removed.
♦ Remove battery tray ⇒ page 15 and retainer for charge pres‐
sure sender.
– Depending on vehicle equipment, unscrew nut -1- from upper
bolt of starter - B- and remove earth cable -2-.
36 Rep. gr.27 - Starter, current supply, CCS
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Electrical system - Edition 04.2019
– Release and disconnect electrical connector -1-.
– Press off cap -2-.
– Unscrew securing nut -3-, and remove line for terminal 30/B+.
– Unscrew nut -4- and remove retainer -1- with wiring harness
attached.
– Unscrew securing bolts -2- and -5- from starter - B- -3-.
– Remove starter - B- -3- upwards.
Installing
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pt
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itte
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3.3.3 Removing and installing starter, vehi‐
rrectness of i
cles with 4-cyl. diesel engine and dual
l purpos
clutch gearbox DQ500
Special tools and workshop equipment required
nf
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♦ Hose clamp pliers - VAS 6340-
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3. Starter motor 37
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1331-
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Removing
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h re
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– If fitted, remove engine cover panel ⇒ Rep. gr. 10 ; Engine
es, in part or in w
cover panel; Removing and installing engine cover panel .
t to the co
– Drain coolant ⇒ Rep. gr. 19 ; Cooling system/coolant; Drain‐
ing and filling coolant .
rrectness of i
– Unscrew bolts -2-.
l purpos
– Disconnect electrical connector -6-.
– Unclip wiring harness -5-.
nform
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– Loosen clips -3-.
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– Unscrew bolts -3-.
AG.
38 Rep. gr.27 - Starter, current supply, CCS
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Remove cover -1- and -2-.
– Detach coolant hose from retainer -5-.
– Pull off vacuum hoses -7- and place to one side.
– Disconnect electrical connector -6-.
WARNING
The fuel line is under pressure.
Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.
– Release fuel hoses -1-.
– Unscrew nut -4-. AG. Volkswagen AG d
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– Remove fuel filter bracket -2- thwith
or
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– Separate electrical connectors -1-, -2- and -3-.
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– Lay wiring harnesses aside.
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3. Starter motor 39
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Electrical system - Edition 04.2019
– Loosen clips -3-.
– Pull off coolant hoses -2-.
– Release valve -1- in bracket -4-.
– Move valve -1- with coolant hoses aside slightly.
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m
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– Unscrew bolt -1-.
40 Rep. gr.27 - Starter, current supply, CCS
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Unscrew nut -2-.
Nut is only accessible from above.
– Remove bracket -1-.
– Unscrew bolt -2-.
Bolt is only accessible from above.
– Remove starter - B- -1- upwards.
Installing wage
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3. Starter motor 41
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Electrical system - Edition 04.2019
4 Cruise control system (CCS)
Note
All instructions and information about this chapter: ⇒ Electrical
system; General information; Rep. gr. 27 ; Cruise control system
(CCS) .
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42 Rep. gr.27 - Starter, current supply, CCS
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
5 Start/stop system
⇒ “5.1 General description - start/stop system”, page 43
⇒ “5.2 Overview of fitting locations - start/stop system”,
page 43
⇒ “5.3 Removing and installing voltage stabiliser”, page 44
5.1 General description - start/stop system
The start/stop system is used for reducing fuel consumption by
automatically switching off the engine when the vehicle is sta‐
tionary and automatically starting it when the driver wants the
vehicle to move on. The start/stop mode is automatically activated
when, after moving on, the vehicle is driven for about 4 seconds
at a minimum speed of 3 km/h.
Battery recharging or jump start on vehicles with start/stop sys‐
tem:
When recharging or jump starting vehicles with start/stop system,
note the following: first connect charging cable to battery positive
terminal then body earth. This ensures that the battery monitor
control unit - J367- is not bridged. Charging the battery directly on
the negative terminal causes the battery monitoring control unit
to be bridged. The battery data is not collected by the battery
monitoring control unit during the charging process. Then, the
values concerning the battery state and saved in the data bus
diagnostic interface would not correspond to the values of the
charged battery.
Renewing battery on vehicles with start/stop system
Note
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♦ Due to higher demands
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cial battery is rused
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♦ When renewing
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the battery, note the correct part designation
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⇒ ETKA .
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♦ Batteries intended for use in vehicles with a start/stop system
rm
ab
are marked “AGM” (Absorbent Glass Mat) or “EFB” (En‐
pe
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hanced Flooded Battery).
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Fault detection and fault display:
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The start/stop system as a function is integrated in the engine
control unit - J623- software.
The engine control unit - J623- features self-diagnosis to facilitate
rrectness of i
fault finding.
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For fault finding, use the systems described in chapter “Vehicle
diagnosis, testing and information system” in “Guided Fault Find‐
nform
ercia
ing” mode ⇒ page 321 .
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5.2 Overview of fitting locations - start/stop
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Note safety precautions ⇒ page 1 .
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5. Start/stop system 43
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Electrical system - Edition 04.2019
1 - Start/stop operation switch
- E693-
❑ Installed in centre of
dash panel.
❑ Removing and installing
⇒ page 252
2 - Engine (motor) control unit
- J623- n AG. Volkswagen AG do
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❑ Installed in electronics yV
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⇒ Power unit; Rep. gr.
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24 ; Engine control unit;
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Removing and installing
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engine control unit J623
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5.3 Removing and installing voltage stabil‐
iser
Note
The voltage stabiliser - J532- has been installed until June 2016.
Role of voltage stabiliser:
Voltage dips occur in the onboard supply system each time the
engine is started due to the high current draw of the starter. To
prevent any failure in the infotainment components and the dash
panel insert when the engine is restarted, the voltage supply to
the infotainment system and the dash panel insert is protected by
means of voltage stabilisation. To do this, terminal 30 is fed
through a DC/DC converter during the starting process and the
voltage is stabilised at 12V. The DC/DC converter is only active
during the actual starting process (terminal 50). For other times,
the converter is bridged with the aid of an internal relay and supply
comes directly from the onboard supply system (terminal 30).
44 Rep. gr.27 - Starter, current supply, CCS
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Electrical system - Edition 04.2019
Effects in case of voltage stabiliser failure:
When the starter is operated and the voltage supply is insufficient
for devices like radio, radio navigation or telephone they will per‐
form a reset. If, in start/stop mode, the mentioned electrical con‐
sumers are identified as causing a reset for each motor start, this
indicates a defective voltage stabiliser. A direct entry regarding a
voltage regulator malfunction, e.g. in the event memory of the di‐
agnostic interface or the onboard supply control unit, does not
occur at present. If radio, radio navigation and telephone units fail
together, first check fuse of voltage regulator.
Location of the voltage stabiliser -arrow- in electronics box on the
left in the engine compartment
Removing
– Switch off ignition and all electrical consumers, and withdraw
ignition key.
– Open electronics box on left side of engine compartment
⇒ page 305 .
– Pull out voltage stabiliser - J532- together with holder in
-direction of arrow-.
– Release and pull off electrical connector on voltage stabiliser
- J532- .
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– Pull voltage stabiliser - J532- -A- in -direction ofss aarrow- out of ac
holder -B-.
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Installation is carried out in the reverse sequence of removal.
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5. Start/stop system 45
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Electrical system - Edition 04.2019
6 Adaptive cruise control
⇒ “6.1 Overview of fitting locations - adaptive cruise control”, page
46
⇒ “6.2 Removing and installing automatic distance control unit”,
page 46
⇒ “6.3 Removing and installing trim for radar sensor”, page 47
⇒ “6.4 Calibrating adaptive cruise control”, page 48
6.1 Overview of fitting locations - adaptive cruise control
1 - Dash panel insert - KX2-
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3 - Securing nuts
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❑ 8 Nm
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4 - Retaining plate with adapter
frame
❑ Serves as mounting
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bracket for adaptive
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cruise control unit -
J428-
❑ With adjuster screws for
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adaptive cruise control
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unit - J428-
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5 - Electrical connector
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6 - Adaptive cruise control unit
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- J428-
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7 - Adaptive cruise control but‐ Prote AG.
ton - E357-
❑ Integrated in multifunc‐
tion steering wheel
❑ Removing and installing
⇒ Communication;
Rep. gr. 91 ; Multifunc‐
tion steering wheel; Removing and installing multifunction buttons in steering wheel -E441- / -E440- .
6.2 Removing and installing automatic dis‐
tance control unit
Special tools and workshop equipment required
46 Rep. gr.27 - Starter, current supply, CCS
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Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1410-
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Removing trim for radar sensor ⇒ page 47 .
Note
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♦ For reasons of clarity, the diagram
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without
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– Release and disconnect electrical connector -3-.
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– Unscrew securing nuts -2-.
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– Remove adaptive cruise control unit - J428- -1- together with
, is n
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bracket forwards out of installation opening in radiator grille.
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spec
Installing
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Install in the reverse order of removal, observing the following:
– After installing, calibrate adaptive cruise control system
rrectness of i
⇒ page 48 .
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Specified torques
♦ ⇒ “6.1 Overview of fitting locations - adaptive cruise control”,
nform
ercia
page 46
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6.3 Removing and installing trim for radar
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♦ The shape of the radar sensor trim depends on the type of cop Vo
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♦ Version -A- for unpainted commercial vehicle bumper covers.
♦ Version -B- for painted bumper covers.
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
6. Adaptive cruise control 47
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Electrical system - Edition 04.2019
– Detach radar sensor trim -1- at fasteners -arrows- and remove.
Installing
Install in reverse order of removal.
6.4 Calibrating adaptive cruise control
– Calibrate adaptive cruise control ⇒ Running gear, axles,
steering; Rep. gr. 44 ; Adaptive cruise control; Calibrating n AG. Volkswagen AG do
adaptive cruise control . olks
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48 Rep. gr.27 - Starter, current supply, CCS
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Electrical system - Edition 04.2019
90 – Gauges, instruments
1 Dash panel insert
⇒ “1.1 Assembly overview - dash panel insert”, page 49
⇒ “1.2 Removing and installing dash panel insert KX2 ”,
page 50
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⇒ “1.3 Removing and installing ambient
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The illustration shows fitting locations for left-hand drive vehicles. Fitting locations for right-hand drive vehicles
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1 - Electrical connector
❑ For dash panel insert
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2 - Dash panel insert - KX2-
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❑ With control unit in dash
panel insert - J285- .
❑ With immobiliser control
nf
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unit - J362-
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❑ Dash panel insert must
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be renewed if warning
or
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lamp LED or illumination
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for dash panel insert is
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❑ Removing and installing
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⇒ page 50
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3 - Securing bolt
❑ Qty. 2
❑ 1.5 Nm
4 - Dash panel insert trim
❑ Removing and installing
⇒ General body repairs,
interior; Rep. gr. 70 ;
Compartments/covers;
Removing and installing
dash panel insert trim .
5 - Gap cover
❑ Part of dash panel insert
trim; clipped into steer‐
ing column trim at top
1. Dash panel insert 49
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Electrical system - Edition 04.2019
1.2 Removing and installing dash panel in‐
sert - KX2-
Special tools and workshop equipment required
♦ Torque screwdriver - V.A.G 1624-
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Note
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♦ If one of the components is defective, the dash panel insert -
K- must be renewed as a complete unit.
rrectne
♦ All indicator lamps in the dash panel insert - K- are equipped
with light-emitting diodes. Light-emitting diodes cannot be re‐
ss
newed separately if defective.
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cial p
f in
♦ The dash panel insert - K- must not be dismantled.
form
mer
♦ For greater clarity, the steering wheel is not shown. However,
atio
om
it is not necessary to remove the steering wheel before re‐
n
c
i
or
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moving the dash panel insert - K- .
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♦ If the dash panel insert - K- with the control unit in dash panel
i
o
pr
cum
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insert - J285- is to be renewed, start the respective function
fo
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⇒ Vehicle diagnostic tester.
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Note
♦ If a new dash panel insert is installed in the vehicle, the control
unit of the dash panel insert must be adjusted to the different
combination possibilities depending on the associated country
settings, number of cylinders and engine type.
♦ To adapt the integrated immobiliser to the engine control unit,
the data from the engine control unit has to be stored in the
replacement dash panel insert.
♦ Select “Renew” function for the respective control unit in “Gui‐
ded Fault Finding” or “Guided Functions” mode ⇒ Vehicle
diagnostic tester.
♦ After installing a new dash panel insert, all ignition keys must
be adapted.
Following components are integrated in the dash panel insert -
KX2- :
♦ Control unit in dash panel insert - J285-
♦ Fuel gauge - G1-
♦ Speedometer - G21-
50 Rep. gr.90 - Gauges, instruments
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Californiaut 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤
ho e o , Transporter 20 ...
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♦ Coolant temperature gauge - G3-
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♦ Rev. counter - G5-
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♦ Warning lamps
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Removing
spec
urposes, in part or in wh
– Move steering wheel to rearmost and lowest position. Use the
t to the co
full range of the steering column adjustment for this purpose.
– Switch off ignition.
rrectne
– Store the ignition key outside the vehicle to prevent the ignition
from being switched on unintentionally.
ss o
cial p
f
– Remove dash panel insert trim ⇒ General body repairs, inte‐
inform
rior; Rep. gr. 70 ; Compartments/covers; Removing and in‐
mer
stalling dash panel insert trim .
atio
om
n
– Remove securing bolts -1-.
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The dash panel insert - KX2- is engaged in the dash panel. There‐
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fore, a greater force is necessary to remove it.
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– Pull out dash panel insert - KX2- -2- until it makes contact with
AG.
steering wheel.
– To separate electrical connector on back of dash panel insert,
press locking detent -1- and swing retaining clip in direction of
-arrow-.
– Remove dash panel insert - KX2- from between steering wheel
and dash panel.
Installing
Install in reverse order of removal.
Specified torques
♦ ⇒ “1.1 Assembly overview - dash panel insert”, page 49
1.3 Removing and installing ambient tem‐
perature sensor
Removing
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Front bumper; Removing and installing bumper
cover .
1. Dash panel insert 51
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Electrical system - Edition 04.2019
– Carefully press together retaining clips -arrow- and pull out
ambient temperature sensor - G17- -2- from retainer.
– Release and disconnect electrical connector -1-.
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Install in the reverse order of removal,
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observing the following: nte
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On completion of repair work,
ss a interrogate event memory and ra
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erase any entries “Guided Fault Finding” ⇒ Vehicle diagnostic
ce
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tester.
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52 Rep. gr.90 - Gauges, instruments
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
n AG. Volkswagen AG do
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2 Clock ir se
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⇒ “2.1 Removing and installing clock”, spage
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2.1 Removing and installing clock
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The clock is integrated in the dash panel insert and cannot be
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removed or renewed individually. In the event of damage, the
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dash panel insert must be renewed ⇒ page 50 .
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2. Clock 53
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Electrical system - Edition 04.2019
3 Horn
⇒ “3.1 Assembly overview - horn”, page 54
⇒ “3.2 Removing and installing horn or dual tone horn H1 / bass
horn H7 ”, page 54
3.1 Assembly overview - horn
Note
Depending on the level of equipment, a single tone horn may be
fitted instead of the dual tone horn.
1 - Securing nut for bass horn
- H7-
❑ 9 Nm
2 - Electrical connector of bass
horn - H7-
3 - Bass tone horn - H7-
❑ Removing and installing
⇒ page 54
4 - Securing nut for horn or du‐
al tone horn - H1-
❑ 9 Nm
5 - Horn or dual tone horn - H1-
❑ Removing and installing agen
AG. Volkswagen AG d
⇒ page 54 Volksw
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6 - Electrical connector of horn orise nte
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or dual tone horn - H1- auth
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3.2 Removing and installing horn or dual
p
cum
or
tone horn - H1- / bass horn - H7-
f
en
ng
t.
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Special tools and workshop equipment required
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54 Rep. gr.90 - Gauges, instruments
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Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1331-
Removing
Note
♦ Depending on the level of equipment, a single tone horn may
be fitted instead of the dual tone horn.
♦ Removal and installation are carried out in the same manner
for all horn types.
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– Remove noise insulation Volunder engine ⇒ General body
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pairs, exterior; Rep.
se
gr.
d by 66 ; Noise insulation . ua
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– Release and disconnect
au
t electrical connector -1-. or
ac
ss
– Unscrew nut -2-.
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– Detach horn -3- from bracket.
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Installing
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Install in the reverse order of removal, observing the following:
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Specified torques
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♦ ⇒ “3.1 Assembly overview - horn”, page 54
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3. Horn 55
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Electrical system - Edition 04.2019
4 Tachograph “DTCO 1381”
⇒ “4.1 General description - tachograph DTCO 1381 ”,
page 56 agen
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⇒ “4.2 Overview of fitting locations - tachograph DTCO d b 1381 ”,
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⇒ “4.3 Removing and installing tachograph DTCOss 1381 ”, c
page 58
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⇒ “4.4 Messages displayed on tachograph DTCO 1381 ”,
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page 60
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⇒ “4.5 Connector pin assignment - tachograph DTCO 1381 ”,
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page 62
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⇒ “4.6 Removing and installing tachograph sender G75 ”,
es, in part or in w
page 63
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4.1 General description - tachograph
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“DTCO 1381”
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Tachograph “DTCO 1381”
The tachograph is installed and sealed by authorised personal.
nform
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Do not modify the unit or any wires.
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♦ Sealing and activating the tachograph - G24- may only be car‐
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or
ried out by authorised specialist workshops in accordance with
f
en
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§ 57b StVZO (German vehicle licensing regulations).
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♦ Additional information and diagnosis instructions for the ta‐
ht
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chograph - G24- can be found in the ⇒ operating manual of
co Vo
by lksw
cted agen
the vehicle and in the ⇒ operating manual of the tachograph. Prote AG.
♦ When retrofitting, repairing or fault finding, observe: ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
Do not insert other types of cards in the card slot, for example
credit cards, cards with embossed lettering or metal cards. They
will damage the card slot of the tachograph.
Access rights to the data stored in the memory of the tachograph
are regulated by legislation and are only released with the corre‐
sponding tachograph card.
Changing roll of paper ⇒ Operating Instructions
If the tachograph has not been activated as a monitoring unit, the
display will show two rectangles, one above the other, next to the
time display. Apart from the workshop card the tachograph will
accept no other tachograph card. Ensure that the tachograph is
immediately and properly brought into operation by an authorised
workshop.
The tachograph cards prescribed by the legislator can be ob‐
tained through the authorities of the EU member states. Colour
marked tachograph cards are available for the following users
according to access rights and use:
Colour of card Application
White Driver card used to share driver identity with tachograph. The driver card is intended for
normal vehicle operation.
yellow Company card used to share identity of company with tachograph and to access company
data. The company card is designed for owners and operators of vehicles.
56 Rep. gr.90 - Gauges, instruments
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Electrical system - Edition 04.2019
Colour of card Application
blue The control card used by authorities (police etc.) to identify themselves to the tachograph
and to access the mass storage of the tachograph.
red The workshop card used by personal of an authorised workshop. This card allows a work‐
shop to perform authorised programming, calibration, activation and checks on a tacho‐
graph.
Locking of tachograph card: a mechanical lock prevents the ta‐
chograph card from being removed after it has been inserted. Vand
accepted by the tachograph. Removal of the tachograph n AG olkswagen AG do
kswage card is es n
only possible when: by
Vol ot g
ua d ran
ise
♦ Ignition is switched »ON« and vehiclethois
r
stationary. tee
or
au ac
♦ On request by the user. ss
ce
le
un
pt
♦ After saving the data defined by the regulation on the tacho‐
an
d
itte
y li
graph card.
erm
ab
ility
ot p
Checking and repairing tachograph
wit
is n
h re
The tachograph must be checked when the following occurs:
ole,
spec
urposes, in part or in wh
♦ Always when changing to different tyres; this is because the
t to the co
effective diameter of the tyres may change.
♦ Always whenever the tachograph is repaired.
rrectne
♦ When the official registration number of the vehicle is
changed.
ss
♦ When the UTC time (universal time coordinated) of the tacho‐
o
cial p
f
graph deviates by more than 20 minutes.
inform
mer
♦ After a period of 2 years (at least every 2 years) the tachograph
atio
m
must be checked by the tachograph manufacturer or a spe‐
o
n
c
cialist workshop authorised by the manufacturer.
i
or
n thi
te
sd
iva
o
pr
cum
Note
r
fo
en
ng
t.
yi Co
op
♦ Checks and repairs on the tachograph - G24- can only be car‐
C py
t. rig
gh
ried out by the tachograph manufacturer or by a specialist
ht
pyri by
Vo
workshop authorised by this manufacturer.
co lksw
by
cted agen
Prote AG.
♦ Sealing and activating the tachograph - G24- may only be car‐
ried out by authorised specialist workshops in accordance with
§ 57b StVZO (German vehicle licensing regulations).
♦ Manipulating the tachograph or its signal functions is an of‐
fence and can be prosecuted.
Fault detection and fault display:
The tachograph “DTCO 1381” is equipped with self-diagnosis.
For fault finding, use the systems described in chapter “Vehicle
diagnosis, testing and information system” in “Guided Fault Find‐
ing” mode ⇒ Vehicle diagnostic tester.
Fault messages are displayed on the tachograph display
⇒ “4.4 Messages displayed on tachograph DTCO 1381 ”,
page 60 .
4.2 Overview of fitting locations - tachograph “DTCO 1381”
4. Tachograph “DTCO 1381” 57
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Electrical system - Edition 04.2019
1 - Dash panel insert - KX2-
❑ Removing and installing
⇒ page 50
2 - Tachograph - G24- “DTCO
1381”
❑ Installed in centre of
dash panel.
❑ Removing and installing
⇒ page 58
❑ Connector pin assign‐
ment ⇒ page 62 .
❑ New version (release
2.2)
n AG. Volkswagen AG do
3 - Printout from tachograph olks
wage es n
ot g
V
❑ Changing roll of paper by ua
ed ran
⇒ Operating Instruc‐ oris tee
th or
tions ss
au ac
ce
e
4 - Tachograph sender - G75-
nl
pt
du
an
itte
❑ Installed on gearbox.
y li
erm
ab
❑ Removing and installing
ility
ot p
⇒ page 63
wit
, is n
h re
❑ Provides real-time sig‐
hole
nals and encrypted data
spec
es, in part or in w
for capturing distance
t to the co
and velocity.
❑ The tachograph can de‐
tect external tampering
rrectness of i
and influences through
data communication
l purpos
and comparison with the
real-time signal.
nf
ercia
❑ Specified torque, vehi‐
rm
m
cles with 5-speed man‐
atio
m
ual gearbox: 6 Nm
o
n in
or c
❑ Specified torque, vehi‐
thi
te
sd
a
cles with 6-speed manual gearbox: 45 Nm
iv
o
r
rp
cu
❑ Specified torque, vehicles with automatic gearbox/dual clutch gearbox: 45 Nm
o
m
f
en
ng
t.
yi Co
5 - Tachograph card . Cop py
rig
ht
❑ Assignment of the different card colours ⇒ page 56 rig ht
py by
co Vo
by lksw
6 - Retrieval software with data exchange connection cted agen
Prote AG.
❑ Reads data on tachograph
❑ Pin assignment for data exchange connection ⇒ page 62
4.3 Removing and installing tachograph
“DTCO 1381”
Note
♦ Depending on the model, the factory-fitted tachograph - G24-
can be installed between the central vents in the dash panel
or in an additional console on the dash panel. The procedure
for removing and installing is the same.
♦ If necessary, remove additional dash panel console ⇒ Rep.
gr. 68 .
58 Rep. gr.90 - Gauges, instruments
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Electrical system - Edition 04.2019
Special tools and workshop equipment required
♦ Release tool - V /160-
– Download tachograph data if tachograph is to be repaired or
renewed. wage
n AG. Volkswagen AG do
e ks s no
Vol t gu
d by ara
e nte
ris
Note utho eo
ra
a c
ss
ce
Repairing or exchanging: the authorised workshop can download
le
un
pt
the tachograph data and hand them over to the respective com‐
an
d
itte
y li
pany/business. If the data cannot be downloaded because of a
rm
ab
defect, the workshop must provide the customer with a certificate
pe
ility
stating this.
ot
wit
, is n
h re
hole
spec
Removing
es, in part or in w
t to the co
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Insert both release tools into the intended openings in the ta‐
rrectness of i
chograph -arrows-, and engage them.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Pull tachograph in -direction of arrows- out of dash panel using cop Vo
by lksw
release tools. cted agen
Prote AG.
4. Tachograph “DTCO 1381” 59
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Release and disconnect the two connectors -arrows-.
Installing:
Installation is carried out in the reverse sequence of removal.
4.4 Messages displayed on tachograph
“DTCO 1381”
This chapter describes the most important messages displayed
on the tachograph and their causes. It is not a replacement for
the self-diagnosis using the ⇒ Vehicle diagnostic tester.
Fault table
Indicated on display: Meaning Measure
Power interruption The power was disconnected or the Continue fault finding via vehicle
power supply to the tachograph or swself-diagnosis.
agen
AG. Volkswagen AG d
oes
distance sender was too low. UnderbyV
olk not
gu
certain circumstances, thisrismes‐
ed ara
nte
sage may also be displayedutho when eo
ra
the engine is started.ss a c
ce
le
Internal fault Serious fault in tachograph. The fol‐ ♦ Check function of switching ele‐
un
pt
an
lowing are possible causes: ments
d
itte
y li
♦ Unexpected programme or pro‐
rm
ab
♦ Check connecting wires to ex‐
pe
cessing time fault.
ility
ternal units.
ot
wit
, is n
♦ Switching elements blocked or
h re
pressed simultaneously for ♦ Check dash panel insert using
hole
spec
some time. self-diagnosis.
es, in part or in w
t to the co
♦ Communication fault with exter‐ ♦ Check tachograph using self-di‐
nal devices. agnosis.
♦ Communication fault with dash ♦ Remove tachograph card and
rrectness of i
panel insert reinsert
l purpos
♦ Fault with pulse output.
nform
ercia
♦ Fault in the card mechanics.
m
a
com
Printer fault The printer supply voltage has ♦ Acknowledge message
ion in
failed or the temperature sensor for
r
te o
♦ Repeat process and, if neces‐
thi
the printing head is defective.
s
iva
sary, switch ignition off and on
do
r
rp
again.
cum
fo
en
ng
t.
yi Co
Download fault Fault while downloading the data to ♦ Acknowledge message Cop py
an external device
t. rig
gh ht
♦ Repeat data download once pyri by
Vo
co
again.
by lksw
cted agen
Prote AG.
♦ Check connecting wires to ex‐
ternal device or external device
itself.
60 Rep. gr.90 - Gauges, instruments
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Electrical system - Edition 04.2019
Indicated on display: Meaning Measure
Card fault A communication fault has occur‐ Clean contacts of tachograph card
red during reading or writing of a and insert it again.
tachograph card, e.g. due to dirty
contacts.
As a result, it is possible that the
data will not be recorded complete‐
ly on the tachograph card.
Printout delayed An ongoing printout is interrupted or Wait until cool. The printout will con‐
delayed because the temperature tinue automatically as soon as the
of the thermal printing head is too permissible condition is reached.
high.
Printout not possible A printout is not possible at the mo‐ Request printout again when fault
ment because: has been rectified.
♦ the ignition is switched off
G. Volkswage
A n AG d
agen oe
olksw ♦ the temperature
s no
t gu of the thermal
yV
ise
db printing headais rantoo high
r tee
tho
s au ♦ or because the supply
or
ac voltage is
s too low.
ce
le
un
pt
an
d
Card error An error has occurred when pro‐ ♦ Clean contacts of tachograph
itte
y li
erm
cessing the tachograph card. The card and insert it again.
ab
ility
tachograph card is not accepted
ot p
♦ If this message is displayed
wit
and is rejected.
is n
again, check whether the tacho‐
h re
ole,
graph card can be read correct‐
spec
urposes, in part or in wh
t to the co ly.
Wrong card The inserted card is not a tacho‐ Insert a valid tachograph card.
graph card. The card is not accep‐
rrectne
ted and is ejected again.
No data The menu function cannot be called This message will disappear after
s
up because: 3 seconds. No measures required.
s o
♦ no driver card is inserted,
cial p
f inform
mer
♦ or a company card / control card
atio
is inserted in the card slot.
om
n
c
i
or
Entry stored Acknowledgement that the tacho‐ This message will disappear after
thi
te
sd
a
graph has saved the entry. 3 seconds. No measures required.
iv
o
pr
cum
r
Display impossible No data can be displayed as long This message will disappear after
fo
en
ng
as the printing is in process. 3 seconds. No measures required.
t.
yi Co
Cop py
Please wait! The tachograph card has not yet This message will disappear after
t. rig
gh ht
yri
been read completely. Menu func‐ 3 seconds. No measures required.
p by
co Vo
by lksw
Prote
cted tions cannot be called up.
AG.
agen
4. Tachograph “DTCO 1381” 61
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
4.5 Connector pin assignment - tachograph
“DTCO 1381” AG. Volkswagen AG d
agen oes
Connector for data exchange on front of unit olksw not
V gu
d by ara
e nte
1- 0 volt reference potential horis
eo
aut ra
2- Not assigned ss c
ce
e
nl
pt
3- RXD data interface, receive
du
an
itte
y li
erm
4- Not assigned
ab
ility
ot p
5- 24 or 12 volt vehicle voltage
wit
, is n
h re
6- TXD data interface, send hole
spec
es, in part or in w
t to the co
Connector “A”
rrectness of i
1- Terminal 30 voltage supply, positive
l purpos
2- Illumination, terminal 58d
nf
ercia
3- Terminal 15 voltage supply, positive
orm
m
atio
4- CAN bus, high
om
n in
c
5- Voltage supply, negative, terminal 31a
or
thi
te
sd
a
6- Terminal 31 voltage supply, negative
iv
o
r
rp
cu
o
m
f
7- CAN bus, negative
en
ng
t.
yi Co
op
8- CAN bus, Low
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
Connector “B” Prote
cted AG.
agen
1- Voltage supply to tachograph sender, positive
2- Voltage supply to tachograph sender, negative
3- Speed signal for tachograph (real time)
4- Data signal for tachograph
5- Not assigned
6- Sender pulse output
7- Speed signal output (PWM)
8- Signal for distance travelled (4 pulses per meter)
Connector “C”
This connector is not used.
62 Rep. gr.90 - Gauges, instruments
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Electrical system - Edition 04.2019
Connector “D”
1- Input for supplementary tachograph, flashing blue light (Hi
level 12 volts: 9-15 V; 24 V: 9-30 V)
2- Input for supplementary tachograph, siren (Hi level 12 volts:
9-15 V; 24 V: 9-30 V)
3- Not assigned
4- Output for TCO warning light (1.5 V, max. 20 mA)
5- Not assigned
6- Not assigned
7- Not assigned
8- Not assigned
4.6 Removing and installing tachograph
sender - G75-
⇒ “4.6.1 Removing and installing tachograph sender G75 , 5-
speed manual gearbox”, page 63
⇒ “4.6.2 Removing and installing tachograph sender G75 , 6-n AG. Volkswagen AG doe
wage
speed manual gearbox”, page 65 yV
olks s no
t gu
b ara
ed
⇒ “4.6.3 Removing and installing tachograph hsender
ris G75 , auto‐ nte
t o e
matic gearbox/dual clutch gearbox”, page s67
au or
ac
s
ce
4.6.1 Removing and installing tachograph
le
un
pt
an
d
sender - G75- , 5-speed manual gear‐
itte
y li
erm
ab
box
ility
ot p
wit
is n
Tachograph sender for 5-speed manual gearboxes.
h re
ole,
spec
urposes, in part or in wh
t to the co
Note
♦ Checks and repairs on the tachograph - G24- can only be car‐
rrectne
ried out by the tachograph manufacturer or by a specialist
workshop authorised by this manufacturer.
♦ Sealing and activating the tachograph - G24- may only be car‐ ss o
cial p
f
ried out by authorised specialist workshops in accordance with
inform
§ 57b StVZO (German vehicle licensing regulations).
mer
atio
m
♦ Additional information and diagnosis instructions for the ta‐
o
n
c
chograph - G24- can be found in the ⇒ operating manual of
i
or
n thi
the vehicle and in the ⇒ operating manual of the tachograph.
te
sd
iva
o
pr
♦ When retrofitting, repairing or fault finding, observe: ⇒ Current
um
r
fo
flow diagrams, Electrical fault finding and Fitting locations.
en
ng
t.
yi Co
op py
♦ Manipulating the tachograph or its signal functions is an of‐ t. C rig
gh ht
fence and can be prosecuted. yri
p by
co Vo
by lksw
cted agen
Prote AG.
Special tools and workshop equipment required
4. Tachograph “DTCO 1381” 63
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Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1783-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
Removing
spec
es, in part or in w
t to the co
Note
rrectness of i
For reasons of clarity, the tachograph sender in the graphic is
shown with the gearbox removed.
l purpos
– Remove anti-tamper seal from tachograph sender.
nform
ercia
– Disconnect connector on tachograph sender.
m
a
com
tio
– Remove tachograph sender -arrow-.
n in
r
te o
thi
Installing
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Install tachograph sender -arrow-, and tighten it to specified
torque.
– Connect connector to tachograph sender.
– Fit anti-tamper seal with wire and aluminium seal on tacho‐
graph sender.
Specified torques
♦ ⇒ “4.2 Overview of fitting locations - tachograph DTCO 1381
”, page 57
64 Rep. gr.90 - Gauges, instruments
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
4.6.2 Removing and installing tachograph
sender - G75- , 6-speed manual gear‐
box
Tachograph sender for 6-speed manual gearboxes
Note
♦ Checks and repairs on the tachograph - G24- can only be car‐
ried out by the tachograph manufacturer or by a specialist
workshop authorised by this manufacturer.
♦ Sealing and activating the tachograph - G24- may only be car‐
ried out by authorised specialist workshops in accordance with
§ 57b StVZO (German vehicle licensing regulations).
♦ Additional information and diagnosis instructions for the ta‐
chograph - G24- can be found in the ⇒ operating manual of
the vehicle and in the ⇒ operating manual of the tachograph.
♦ When retrofitting, repairing or fault finding, observe: ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
♦ Manipulating the tachograph or its signal functions is an of‐
fence and can be prosecuted.
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Special tools and workshop ised bequipment required ara
nte
or eo
h
♦ Torque wrench - V.A.G
aut 1331- ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
– Remove anti-tamper seal from tachograph sender.
nform
ercia
– Disconnect connector -arrow- on tachograph sender.
m
a
com
tion in
– Destroy the plastic cap enclosing the tachograph sender.
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4. Tachograph “DTCO 1381” 65
. Volkswagen AG
gen AG does
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter
olks
wa 20 ... not
yV gu
Electrical system - Edition 04.2019 ised b ara
nte
r
ho eo
ut ra
– Remove tachograph sender -arrow-. ss
a c
ce
le
un
Installing
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– If the tachograph sender is be removed and fitted to another
gearbox (replacement gearbox or new gearbox), first remove
nform
ercia
the M18 bolt with washer -arrow- from the new gearbox.
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Install tachograph sender -arrow-, and tighten it to specified
torque.
– Fit a new cap -1- in -direction of arrow- onto tachograph sender
until it audibly engages.
66 Rep. gr.90 - Gauges, instruments
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Electrical system - Edition 04.2019
– When fitting the cap, align it so that the sealing tab -arrow- on
the cap is pointing in the opposite direction to the diesel par‐
ticulate filter.
– Attach anti-tamper seal on tachograph sender.
Specified torques
♦ ⇒ “4.2 Overview of fitting locations - tachograph DTCO 1381
”, page 57
4.6.3 Removing and installing tachograph
sender - G75- , automatic gearbox/dual
clutch gearbox
Tachograph sender for automatic gearbox/dual clutch gearbox
G. Volkswagen
nA AG do
wage es n
Volks ot g
by ua
ed ran
Note oris tee
h
ut or
ac
sa
♦ Checks and repairs on the tachograph - G24- can only be car‐
s
ce
e
ried out by the tachograph manufacturer or by a specialist
nl
pt
du
an
workshop authorised by this manufacturer.
itte
y li
erm
ab
♦ Sealing and activating the tachograph - G24- may only be car‐
ility
ot p
ried out by authorised specialist workshops in accordance with
wit
, is n
§ 57b StVZO (German vehicle licensing regulations).
h re
hole
spec
♦ Additional information and diagnosis instructions for the ta‐
es, in part or in w
chograph - G24- can be found in the ⇒ operating manual of
t to the co
the vehicle and in the ⇒ operating manual of the tachograph.
♦ When retrofitting, repairing or fault finding, observe: ⇒ Current
rrectness of i
flow diagrams, Electrical fault finding and Fitting locations.
l purpos
♦ Manipulating the tachograph or its signal functions is an of‐
fence and can be prosecuted.
nform
mercia
Special tools and workshop equipment required
at
om
ion
c
♦ Torque wrench - V.A.G 1331-
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Remove anti-tamper seal from tachograph sender.
4. Tachograph “DTCO 1381” 67
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Disconnect connector -arrow- on tachograph sender.
– Destroy the plastic cap enclosing the tachograph sender.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
– Remove tachograph
auth sender -1-. or
ac
ss
Installing
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– If the tachograph sender is be removed and fitted to another
gearbox (replacement gearbox or new gearbox), first remove
the M18 bolt with washer -arrow- from the new gearbox.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Install tachograph sender -1-, and tighten it to specified torque.
68 Rep. gr.90 - Gauges, instruments
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Electrical system - Edition 04.2019
– Fit a new cap -1- in -direction of arrow- onto tachograph sender
until it audibly engages.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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– Attach anti-tamper seal on tachograph sender.
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♦ ⇒ “4.2 Overview of fitting locations - tachograph DTCO 1381
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4. Tachograph “DTCO 1381” 69
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Electrical system - Edition 04.2019
92 – Windscreen wash/wipe system
1 windscreen wiper system.
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⇒ “1.8 Removing and installing rain and light sensor”, page 81
1.1 Assembly overview - windscreen wiper system
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The illustration shows fitting locations for left-hand drive vehicles. Fitting locations for right-hand drive vehicles
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70 Rep. gr.92 - Windscreen wash/wipe system
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
1 - Wiper blade on front pas‐
senger side
❑ Removing and installing
⇒ page 72
2 - Wiper blade on driver side
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❑ Removing and installing
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⇒ page 76
8 - Wiper motor - V-
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❑ Means of securing wiper Prote AG.
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❑ 8 Nm
11 - Wiper arm on front passenger side
❑ Removing and installing ⇒ page 73
❑ Adjusting ⇒ page 74
1.2 Moving wipers to service position
Caution
Risk of damaging the bonnet when moving wipers back into
the park position.
♦ Do not manoeuvre the vehicle with wiper arms folded out.
♦ The wipers automatically move back to the park position
when the wiper switch is operated or when road speed
exceeds 6 km/h.
1. windscreen wiper system. 71
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If it is necessary for the windscreen wiper motor to run during the
working procedure, the bonnet must be closed completely, as
otherwise the power supply to the wiper motor will be interrupted.
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To remove wiper blades, wiper arms must be moved to “service
position”.
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– Switch on ignition briefly, then switch it off again.
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– Actuate windscreen wiper lever in “flick wipe” position within
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• The wipers are moving to “service position”.
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Removing Prote AG.
– Move wipers to service position ⇒ page 71 .
Caution
Risk of damage to the wiper blade.
♦ Joint-free wipers are very flexible. To lift the wiper blades
off the windscreen, touch them only in the area in which
the wiper blades are attached to the wipers.
– Lift wiper arm off the windscreen.
– Press retaining clip -arrow A- and push wiper blade -1- off
wiper arm -2- -arrow B-.
– Remove wiper blade -1-.
Installing
Install in the reverse order of removal, observing the following:
72 Rep. gr.92 - Windscreen wash/wipe system
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Insert wiper blade -1- in parallel movement into wiper arm
-2- -arrow-. Ensure that wiper blade -1- is pushed into wiper
arm -2- until retaining clip is heard to engage.
To leave the “service position”:
– Operate windscreen wiper switch. OR
– Drive vehicle faster than 6 km/h.
1.4 Removing and installing wiper arms
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
♦ Puller - T10369-
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Removing
Caution
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Risk of damage to wiper shafts.
♦ There is a risk of damage to the wiper shafts when trying
nform
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to release the wiper arms without using the puller -
T10369/1- .
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1. windscreen wiper system. 73
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California 2016 ➤ , Caravelle 2016 ed➤ , Multivan 2016 ➤ , Transporter 20
b ara...
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Electrical system - Edition 04.2019
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hole
spec
♦ Removal and installation are described for left-hand drive ve‐
es, in part or in w
t to the co
hicles. Removal and installation for right-hand drive vehicles
is similar.
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– Move wipers to service position ⇒ page 71 .
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– Using a screwdriver, lever caps -3- off wiper arms -1-.
– Loosen nuts -2- a few turns.
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– Fit puller - T10369/1- to wiper arm -1- as shown in illustration.
– Fit thrust piece -2- on wiper shaft.
– Turn bolt -3- clockwise until wiper arm -1- is pulled off wiper
shaft.
– Unscrew nut completely and remove wiper arm -1-.
Installing
Install in the reverse order of removal, observing the following:
– Adjust wiper arms ⇒ page 74 .
1.5 Adjusting wiper arms
Special tools and workshop equipment required
74 Rep. gr.92 - Windscreen wash/wipe system
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1331-
AG. Volkswagen AG d
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– Removing wiper arm ⇒ page 73 .
t to the co
– Switch on ignition.
– Actuate “flick wipe” function and allow wiper motor to move to
rrectne
its end position.
– Switch off ignition.
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– Fit wiper arm together with attached wiper blade onto wiper f inform
shaft.
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– Align wiper blade as follows against the windscreen:
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♦ Dimension -a- = 25 mm + 10 mm.
AG.
♦ Dimension -b- = 25 mm ± 10 mm.
1. windscreen wiper system. 75
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Electrical system - Edition 04.2019
– Tighten nuts -2- for wiper arms -1-.
– Switch on ignition.
– Actuate “flick wipe” function and allow wiper arms move to their
end position.
– Switch off ignition.
– Check wiper arm adjustment again and correct, if necessary.
– Press caps -3- onto wiper arms.
Specified torques
♦ ⇒ “1.1 Assembly overview - windscreen wiper system”,
page 70
1.6 Removing and installing wiper frame
with linkage and wiper motor - V-Volkswa
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Special tools and workshop equipment required
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Removing
The removal and installation procedure is described for left-hand
drive vehicles. Removal and installation for right-hand drive ve‐
hicles is similar.
– Move windscreen wipers to park position.
– Switch off ignition and all electrical consumers, and withdraw
ignition key.
– Removing wiper arm ⇒ page 73 .
76 Rep. gr.92 - Windscreen wash/wipe system
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Electrical system - Edition 04.2019
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Plenum chamber cover; Removing and
installing plenum chamber cover .
– Remove securing bolts -arrows-.
– Release and disconnect connector on wiper motor.
– Remove wiper frame with linkage and wiper motor - V- up‐
wards from plenum chamber.
Installing
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Install in the reverse order of removal, observing the following:
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♦ ⇒ “1.1 Assembly overview - windscreen wiper system”,
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page 70
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1.7 Renewing wiper motor
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Special tools and workshop equipment required
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♦ Release lever - 80-200-
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1. windscreen wiper system. 77
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Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1331-
AG. Volkswagen AG d
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WARNING
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Danger of injury!
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♦ Risk of crushing injuries when performing work on uncov‐
spec
ered windscreen wiper system.
es, in part or in w
t to the co
♦ The windscreen wiper system may only be operated after
its proper installation.
rrectness of i
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Caution
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There is a risk of damage to the bonnet and the wiper arms.
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♦ Before operating the windscreen wiper system with open ion
c
bonnet, ensure that there is sufficient space for the com‐
in t
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ponents to move.
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In order to be able to operate the windscreen wiper system with cted agen
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open bonnet, the bonnet lock must be engaged in position
»closed«.
The removal and installation procedure is described for left-hand
drive vehicles. Removal and installation for right-hand drive ve‐
hicles is similar.
Removing
– Removing wiper arm ⇒ page 73 .
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Plenum chamber cover; Removing and
installing plenum chamber cover .
Note
♦ To remove the wiper motor - V- from the wiper frame, none of
the four bolts securing the wiper motor may be concealed by
the motor crank.
♦ Before removing the wiper motor, switch on the windscreen
wipers and have a second fitter watch the motor crank on the
wiper motor - V- . Switch off the ignition when the motor crank
reaches the “12 o'clock” position and none of the four bolts
securing the wiper motor are concealed.
78 Rep. gr.92 - Windscreen wash/wipe system
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Release and disconnect connector on wiper motor.
– Lever drive rods for wiper arms off wiper motor crank using
removal lever - 80-200- or a suitable levering tool.
– Unscrew four securing bolts -arrows- and remove wiper motor
from wiper frame.
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On vehicles with an anti-theft
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or
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ss
wiper motor.
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On new wiper motors, the motor crank is set to the correct instal‐
es, in part or in w
t to the co
lation position. Do not operate the wiper motor electrically until
the entire windscreen wiper unit has been installed.
rrectness of i
– On new wiper motor -1- unscrew securing bolts -2- from pre-
l purpos
tapped holes in bracket.
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– Lubricate seals -1- (small outer diameter) and -2- (larger outer Prote AG.
diameter) using grease from repair kit.
– Insert wiper motor into bracket of wiper frame -2- and align to
fasteners accordingly.
– Fit upper part of bracket -1- and start self-tapping securing
bolts -3-. When installing, ensure that bolts are not canted in
pre-tapped holes, and ensure that upper part of bracket en‐
gages correctly in wiper frame.
– Tighten securing bolts.
1. windscreen wiper system. 79
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– Press lubricated seal -1- (small outer diameter) over ball head
of motor crank -2- for wiper motor -3-.
Note
Make sure seal is in correct installation position when installing.
– Press drive rod -arrow- of right windscreen wiper -1- over ball
head of motor crank.
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– Press lubricated seal -2- (larger outer diameter) onto drive wrod
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Make sure seal is in correct installation position when installing.
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– Press drive rod -arrow- of left windscreen wiper -1- onto ball
head of motor crank.
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– Connect connector to wiper motor and engage it.
l purpos
– To maintain end position of wiper motor, switch on wiper to
stage 1 for approx. 3 seconds.
nform
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– Switch off ignition and install plenum chamber cover and wiper
m
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arms ⇒ page 73 .
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♦ ⇒ “1.1 Assembly overview - windscreen wiper system”,
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80 Rep. gr.92 - Windscreen wash/wipe system
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
1.8 Removing and installing rain and light
sensor
⇒ “1.8.1 Removing and installing rain and light sensor G397 / rain
sensor G213 ”, page 81
1.8.1 Removing and installing rain and light
sensor - G397- / rain sensor - G213-
Note
♦ The rain and light sensor has a silicon layer (coupling pad)
which forms the contact surface to the windscreen.
♦ The rain and light sensor has been designed so that it can be
used again. A prerequisite for re-use is that the coupling pad
is not damaged or dirty (check!).
♦ If a rain sensor is renewed and has to be replaced by a rain
sensor with another part number, the rain sensor must be co‐
ded ⇒ page 83 .
♦ The rain sensors cannot be installed optionally. Determine
which rain sensor is the right one by referring to ⇒ Electronic
parts catalogue (ETKA) .
Removing
– Switch off ignition and all electrical consumers.
– Store the ignitionagkey
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– Removeho
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gr.aut 68 ; Interior mirror; Removing and installing interior
r a mirror .
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Wait for at least 1 minute after releasing the retaining clip. This is
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is n
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and will not be damaged during removal.
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– Release retaining clip on left and right -arrows-.
t to the co
– Starting from top, carefully lever rain and light sensor - G397-
-1- out of retaining frame on windscreen.
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1. windscreen wiper system. 81
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Electrical system - Edition 04.2019
n AG. Volkswagen AG do
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– Disconnect connector -1- from rain and light sensor - G397-
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the coupling pad cannot be damaged or soiled from dust
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Installing
Install in the reverse order of removal, observing the following:
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Caution
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♦ Prior to installation, thoroughly clean the surface of the
orm
windscreen within the retaining frame for rain and light
m
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sensor - G397- . Make sure to completely remove any re‐
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mains of the coupling pad adhering to the windscreen.
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If the surface of the coupling pad on the rain and light sensor -
G397- is soiled, it may be possible to clean it by “bonding on” and
then “pulling off” one or more adhesive strips.
– Thoroughly clean windscreen in area of retaining plate.
– If fitted, remove protective cap -1- from new rain and light sen‐
sor - G397- .
– Push grip in direction of arrow -A-.
– Remove protective cap -1- in direction of arrow -B-.
82 Rep. gr.92 - Windscreen wash/wipe system
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Electrical system - Edition 04.2019
– Insert rain and light sensor - G397- -1- into retaining frame on
windscreen.
– Push in retaining clip on both sides -arrows- until it engages
audibly.
– Connect connector and engage it.
Note
♦ Even when rain and light sensor - G397- is installed correctly,
small air bubbles may initially appear between windscreen and
coupling pad. After approx. 10 minutes, the contact surface
must be free of bubbles.
♦ If the contact surface is not free of bubbles after 10 minutes,
the rain and light sensor - G397- must be removed and instal‐
led anew.
♦ Air bubbles between the windscreen and the coupling pad will
cause the rain and light sensor - G397- to malfunction.
– Read event memory and delete sporadic faults of the rain
sensor ⇒ Vehicle diagnostic tester.
Note
With the rain sensor disconnected, it is possible to wake the CAN
bus e.g. by opening the door. The sporadic event entries in the
onboard supply control unit must be deleted following repair work.
n AG. Volkswagen AG do
wage es n
– If the rain and light sensor - G397- wasy Vrenewed,
olks
perform cod‐ ot g
ua
ing ⇒ page 83 . ir se
d b ran
o tee
th
Coding rain and light sensor - G397-au or
ac
ss
ce
– Connect vehicle diagnostic tester ⇒ page 321 .
e
nl
pt
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an
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– Code rain and light sensor - G397- ⇒ Vehicle diagnostic tester.
y li
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1. windscreen wiper system. 83
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
2 Windscreen washer system
⇒ “2.1 Assembly overview - windscreen washer system”,
page 84
⇒ “2.2 Removing and installing filler pipe for washer fluid reser‐
voir”, page 85
⇒ “2.3 Removing and installing washer fluid reservoir”,
page 86
⇒ “2.4 Removing and installing windscreen washer fluid level
sender”, page 89
⇒ “2.5 Removing and installing windscreen washer pump”,
page 89 AG. Volkswagen n AG do
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⇒ “2.6 Removing and installing washer yjets”,
Vol page 90 ot g
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⇒ “2.7 Adjusting spray jets”, pagetho90
ris tee
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2.1 Assembly overview
s
- windscreen wash‐
ce
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♦ For additional information refer to ⇒ Maintenance ; Booklet ;
es, in part or in w
Descriptions of work .
t to the co
♦ The size of the washer fluid reservoir may vary and depends
on which headlight washer system is installed.
rrectness of i
♦ Removal and installation of both washer fluid reservoirs is car‐
ried out in the same way.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
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for
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Prote AG.
84 Rep. gr.92 - Windscreen wash/wipe system
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
1 - Spray jets for windscreen
washer system
❑ Removing and installing
⇒ page 90
❑ Adjusting ⇒ page 90
2 - Connection piece
❑ Connection to spray jet
for windscreen washer
system
❑ Overview of hose cou‐
plings for washer fluid
lines ⇒ page 113
3 - Y-piece
❑ Distribution of wash wa‐
ter line to windscreen
washer system spray
jets
4 - Hose
❑ Hose repair
⇒ page 113 AG. Volkswagen AG d
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lksw not
5 - Washer fluid reservoir byV
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ed
❑ The size of the reservoir horis nte
eo
depends on which s aut ra
c
headlight washer sys‐ s
ce
e
tem is installed.
nl
pt
du
an
itte
❑ Removing and installing
y li
erm
ab
⇒ page 86
ility
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❑ Securing bolts for wash‐
wit
, is n
er fluid reservoir: 4.5 Nm
h re
hole
spec
6 - Windscreen and rear win‐
es, in part or in w
dow washer pump - V59-
t to the co
❑ On vehicles without rear
window washer system
rrectness of i
windscreen washer
pump - V589-
l purpos
❑ Removing and installing ⇒ page 89
❑ In event of damage, renew sealing grommet at transition to washer fluid reservoir
nform
ercia
7 - Connection piece
m
at
om
❑ Connection to windscreen and rear window washer pump
on
c
in t
or
❑ Colour coding »black«, washer fluid line to windscreen
his
ate
do
riv
❑ Overview of hose couplings for washer fluid lines ⇒ page 113
p
cum
for
8 - Filler pipe for washer fluid reservoir
en
ng
t.
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op
❑ Removing and installing filler pipe ⇒ page 85 C py
ht. rig
rig ht
❑ Check seal at base of filler pipe for signs of damage, renew if necessary. py by
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❑ Securing bolt for filler pipe: 2 Nm cted agen
Prote AG.
❑ Securing bolts for coolant expansion tank: 2 Nm
2.2 Removing and installing filler pipe for
washer fluid reservoir
Special tools and workshop equipment required
2. Windscreen washer system 85
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Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1783-
Removing
– Drain washer fluid reservoir until water level has dropped be‐
low opening for filler pipe.
– Unscrew securing bolts -1- of coolant expansion tank and
push coolant expansion tank to one side.
– Unscrew securing bolt -2- of filler pipe -3-.
– Pull filler pipe downwards out of washer fluid reservoir and re‐
move it upwards.
Installing agen
AG. Volkswagen AG d
oes
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V
Installation is carried out in the reverse d by order. When installing ob‐ gu
ara
serve the following: rise nte
tho eo
au ra
– Check seal at base of fillerss pipe for signs of damage, renew if c
ce
le
necessary.
un
pt
an
d
itte
– Insert filler pipe in washer fluid reservoir onto stop (use lubri‐
y li
erm
ab
cation if necessary). Note position of anti-rotation tab when
ility
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doing this.
wit
is n
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– Screw in and tighten securing bolt -2- for filler pipe -3- and
ole,
spec
securing bolts -1- for coolant expansion tank.
urposes, in part or in wh
t to the co
Specified torques
♦ ⇒ “2.1 Assembly overview - windscreen washer system”, page
84
rrectne
2.3 Removing and installing washer fluid
ss o
reservoir
cial p
f inform
mer
atio
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Note
o
n
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♦ On vehicles with a headlight washer system, a reservoir with
iv
o
pr
approx. 5 litre capacity is installed. On vehicles without a
um
r
fo
headlight washer system, the reservoir capacity is approx. 4
en
ng
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litres.
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♦ Removal and installation for both versions is basically the yri
p by
o Vo
same.
c by lksw
cted agen
Prote AG.
Special tools and workshop equipment required
86 Rep. gr.92 - Windscreen wash/wipe system
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1783-
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Removing and installing filler pipe for washer fluid reservoir
⇒ page 85 .
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Removing and installing bumper cover .
– Starting at front, detach front left wheel housing liner until
washer fluid reservoir is accessible ⇒ General body repairs,
exterior; Rep. gr.sw66 AG. Volkswagen AGliner;
age;nWheel housing does Removing and
installing front
by
Vowheel
lk housing liner . not
gu
d ara
se n
– Releasetho and pull off electrical connectors -2-, -5- and
ri tee -7- from
or
pumps.
s au ac
s
ce
e
– Release and pull off hose connection pieces -3-, -4- and -6-
nl
pt
du
on windscreen and rear window washer pump - V59- and
an
itte
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headlight washer system pump - V11- .
erm
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ility
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– Collect leaking fluid in accordance with regulations.
wit
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– Detach lines from fasteners on reservoir -arrows-.
hole
spec
es, in part or in w
t to the co
rrectness of i
– Release and separate electrical connector -2- on windscreen
l purpos
washer fluid level sender - G33- .
nf
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orm
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py by
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Prote AG.
2. Windscreen washer system 87
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Electrical system - Edition 04.2019
– Unscrew upper right securing bolt -1- on reservoir on longitu‐
dinal member.
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
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– Unscrew securing bolt -2- of reservoir in wheel housing.
es, in part or in w
t to the co
rrectness of i
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tion in
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te o
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– Unscrew front securing bolt -3- on reservoir. um
fo
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– Pull off washer fluid reservoir downwards.
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Installing
ht
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Installation is carried out in the reverse order. When installing ob‐
cted agen
Prote AG.
serve the following:
Note
The connections to the pump and hose lines are colour-coded in
order to prevent the washer fluid lines being incorrectly connected
to the front and rear washer fluid pump - V59- . The hose unions
must be connected to the correct colour-coded pump connections
during installation.
– Secure lines as per installation markings on lines -arrows- on
reservoir.
– Check seal between washer fluid reservoir and filler pipe for
signs of damage; renew if necessary.
– Insert filler pipe in washer fluid reservoir onto stop (use lubri‐
cation if necessary). When doing this, note position of anti-
rotation tab.
Specified torques
♦ ⇒ “2.1 Assembly overview - windscreen washer system”, page
84
88 Rep. gr.92 - Windscreen wash/wipe system
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
2.4 Removing and installing windscreen
washer fluid level sender
Note
♦ The windscreen washer fluid level sender - G33- is perma‐
nently integrated in the washer fluid reservoir on the engine
side and cannot be replaced individually.
♦ In the event of damage, the washer fluid reservoir must be
renewed ⇒ page 86 .
2.5 Removing and installing windscreen
washer pump
AG. Volkswagen AG d
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agen oes
not
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d
♦ The windscreen and rear window washer pump orise - V59- is nte
eo
mounted on the washer fluid reservoir on a the front left in front
th
u ra
c
of the wheel housing. ss
ce
e
nl
pt
du
♦ On vehicles without a rear window washer system, the wind‐
an
itte
screen washer pump - V589- is fitted with just one hose
y li
erm
ab
connection.
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Removing
hole
spec
– Open service flap in front left wheel housing liner.
es, in part or in w
t to the co
– Release and disconnect connector -2- on windscreen and rear
window washer pump - V59- .
rrectness of i
– Release black hose connecting piece -4- (windscreen) and
pull off white hose connecting piece -3- (rear window) from
l purpos
windscreen and rear window washer pump - V59- -5-.
– Collect leaking fluid in accordance with regulations.
nf
ercia
or
– Pull pump -5- upwards out of reservoir.
m
m
atio
om
– Check sealing grommet for damage and renew if necessary. n in
or c
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Installing
t
sd
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Install in the reverse order of removal. When doing this, note the
o
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en
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following:
t.
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Note
co Vo
by lksw
cted agen
Prote AG.
The connections to the pump and hose lines are colour-coded in
order to prevent the washer fluid lines being incorrectly connected
to the front and rear washer fluid pump - V59- . The hose unions
must be connected to the correct colour-coded pump connections
during installation.
2. Windscreen washer system 89
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Electrical system - Edition 04.2019
2.6 Removing and installing washer jets
Removing
Note
Removal and installation are described for the left side. The re‐
moval and installation procedure for the right-hand side is basi‐
cally the same. agen
AG. Volkswagen AG d
o
ksw es n
Vol ot g
by ua
– Open bonnet. ris
ed ran
tee
tho or
– Push spray jet upwards -arrow A-
ss
and pull out of flap at the au ac
rear -arrow B-.
ce
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un
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itte
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es, in part or in w
t to the co
rrectness of i
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– Release hose clip -1- in direction of -arrow-, and pull hose
connection -2- off spray jet -4-.
nform
ercia
– Release and detach connector -3- and remove spray jet -4-.
m
a
Installing
com
tion in
r
Install in the reverse order of removal, observing the following:
te o
thi
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Note
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t.
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When connecting the washer fluid line, ensure that the securing
t. rig
gh ht
yri
clip engages audibly in the connection.
p by
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by c lksw
cted agen
Prote AG.
– Starting at the top, push spray jet into mounting hole until it
locks in place audibly.
– Adjusting spray jets ⇒ page 90 .
2.7 Adjusting spray jets
Caution
Risk of damage.
♦ Never use items to clean the washer jets!
Note
In case of uneven spray field due to impurities in the spray jet:
remove spray jet and rinse it through with water, opposite to di‐
rection of spray. Subsequent blowing through with compressed
air against the spraying direction is permitted. Never use items to
clean the washer jets!
90 Rep. gr.92 - Windscreen wash/wipe system
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
3-jet nozzle
– Adjust 3-jet nozzle according to the following table:
Ite Dimension -A- in cm meas‐ Dimension -B- in cm meas‐
m ured from upper edge of ured from driver side edge
windscreen of windscreen
1 40 16
2 19 42
3 27 76
4 27 73
5 20 109
6 50 139
Adjusting windscreen washer system spray jets ⇒ Maintenance ;
Booklet 20.1 ; Descriptions of work
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
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u or
a ac
ss
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un
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itte
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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a
com
tion in
r
te o
thi
s
iva
do
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cum
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en
ng
t.
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Cop py
t. rig
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pyri by
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by
cted agen
Prote AG.
2. Windscreen washer system 91
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Electrical system - Edition 04.2019
3 Rear window wiper system
⇒ “3.1 Assembly overview - rear window wiper system”,
page 92
⇒ “3.2 Removing and installing wiper blade”, page 94
⇒ “3.3 Removing and installing wiper arm”, page 95
⇒ “3.4 Adjusting wiper arm”, page 97
⇒ “3.5 Removing and installing rear window wiper motor V12 ”,
page 99
3.1 Assembly overview - rear window wiper
system
⇒ “3.1.1 Assembly overview - rear window wiper system, vehicles
with rear lid”, page 92
. Volkswagen AG
⇒ “3.1.2 Assembly overview - rear window wiper system, vehicleskswagen AG does
not
with rear wing doors”, page 93 Vol gu
by ara
ed nte
ris
3.1.1 Assembly overview - rear window wiper system, vehicles with rear lid au
tho eo
ra
ss c
ce
le
un
pt
1 - Rubber seal
an
d
itte
y li
❑ Install with marking fac‐
erm
ab
ility
ing upwards (tolerance
ot p
wit
-a- = ±10°).
is n
h re
ole,
2 - Tailgate
spec
urposes, in part or in wh
3 - Securing nuts
t to the co
❑ 8 Nm
4 - Hose connection for rear
rrectne
window washer system
s
5 - Rear window wiper motor -
s o
V12-
cial p
f inform
❑ Removing and installing
mer
⇒ page 99
atio
om
6 - Wiper arm shaft n
c
i
or
n thi
e
❑ Moisten with lubricant
t
sd
va
polyethylene glycol
i
o
pr
cum
r
when installing.
fo
en
ng
t.
yi
❑ Wiper arm securing nut:
Co
op py
12 Nm
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
92 Rep. gr.92 - Windscreen wash/wipe system
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Electrical system - Edition 04.2019
3.1.2 Assembly overview - rear window wiper system, vehicles with rear wing
doors
1 - Rubber seal
❑ Install with marking fac‐
ing upwards (tolerance
-a- = ±10°).
2 - Left rear wing door
3 - Rear window wiper motor,
left rear wing door - V92-
❑ Removing and installing
⇒ page 101
4 - Securing bolts
❑ 8 Nm
5 - Hose connection for rear
window washer system
6 - Rear window wiper motor,
right rear wing door - V93-
❑ Removing and installing
⇒ page 100
7 - Rear window wiper arm
shafts gen AG
. Volkswagen AG
swa does
❑ Moisten with lubricant
y Volk not
gu
polyethylenerisedglycol
b ara
nte
when installing.
ut
ho eo
ra
a
❑ Wipers arm securing nut:
s c
ce
le
12 Nm
un
pt
an
d
itte
8 - Right rear wing door
y li
erm
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spec
urposes, in part or in wh
t to the co
rrectness o
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f inform
mer
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n
c
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sd
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cum
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fo
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ng
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Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.
3. Rear window wiper system 93
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Electrical system - Edition 04.2019
3.2 Removing and installing wiper blade
⇒ “3.2.1 Removing and installing wiper blade, vehicles with rear gen AG. Volkswagen AG d
a
lid”, page 94 Vol
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oes
not
g y ua
db ran
⇒ “3.2.2 Removing and installing wiper blade, vehicles riswith rear
e
tee
wing doors”, page 94 utho or
a ac
ss
3.2.1 Removing and installing wiper blade,
ce
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nl
pt
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an
vehicles with rear lid
itte
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WARNING
, is n
h re
hole
spec
♦ Joint-free wipers are very flexible. To lift the rear window
es, in part or in w
wiper blades off the rear window, touch them only in the
t to the co
area in which the rear window wiper blades are attached
to the rear window wipers.
rrectness of i
♦ Avoid bending rear window wiper arm and blade.
l purpos
♦ Prevent rear window wiper arm from springing back unin‐
tentionally and damaging the glass.
nf
ercia
orm
m
Removing
atio
om
n in
c
– Allow rear window wiper to adopt park position.
or
thi
te
sd
a
– Switch off ignition and all electrical equipment and then re‐
iv
o
r
rp
cu
move ignition key.
o
m
f
en
ng
t.
yi
– Fold rear window wiper arm -1- away from rear window.
Co
Cop py
t. rig
gh
– Swivel rear window wiper blade in -direction of arrow A-.
ht
pyri by
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by
– Press release button -2- and pull rear window wiper blade on cted agen
Prote AG.
rear window wiper blade fastener -1- in -direction of arrow B-
out of rear window wiper arm.
Installing
– Install in the reverse order of removal. When doing this, note
the following:
– Fold back rear window wiper arm.
– Check rear window wiper blade parking position and adjust if
necessary ⇒ page 97 .
3.2.2 Removing and installing wiper blade,
vehicles with rear wing doors
Caution
♦ Joint-free wipers are very flexible. To lift the rear window
wiper blades off the rear window, touch them only in the
area in which the rear window wiper blades are attached
to the rear window wipers.
♦ Avoid bending rear window wiper arm and blade.
♦ Prevent rear window wiper arm from springing back unin‐
tentionally and damaging the glass.
Removing
– Allow rear window wiper to adopt park position.
94 Rep. gr.92 - Windscreen wash/wipe system
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Electrical system - Edition 04.2019
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Fold rear window wiper arm -1- away from rear window.
– Fold rear window wiper blade -2- 90° towards rear window
wiper arm -1- and back again.
– Pull plastic cap off rear window wiper arm -arrow 1-.
– Remove rear window wiper blade -2- in -direction of arrow 2-
from rear window wiper arm axis -1-.
Installing
– Install in the reverse order of removal. When doing this, note
the following:
– Push rear window wiper blade -2- in -direction of arrow 1- onto
rear window wiper arm axis -1-.
– Fit plastic cap and engage it -arrow 2- to secure rear window
wiper blade in position.
– Fold back rear window wiper arm.
– Check rear window wiper blade parking position and adjust if
necessary ⇒ page 97 .
3.3 Removing and installing wiper arm
wage
n AG. Volkswagen AG do
e
olks s no
V t gu
⇒ “3.3.1 Removing and installing wiper arm, vehicles
ed
by with rear lid”, ara
page 95 h oris nte
eo
t
au ra
⇒ “3.3.2 Removing and installing wiperssarm, vehicles with rear c
wing doors”, page 96
ce
le
un
pt
an
d
itte
3.3.1 Removing and installing wiper arm, ve‐
y li
erm
ab
hicles with rear lid
ility
ot p
wit
is n
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Special tools and workshop equipment required
ole,
spec
urposes, in part or in wh
♦ Puller - T10369-
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
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ng
t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.
3. Rear window wiper system 95
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Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1331-
Removing
– Switch on ignition.
– Actuate “rear window wipe” function and allow wiper arm to
move to its end position. en AG. V
olkswagen AG
ag does
lksw not
– Switch off ignition and remove ignition key.
by
Vo gu
ara
ed nte
ris
– Press together cap of rear windowutwiper
ho -1- in direction of ar‐ eo
ra
row -A-. ss a c
ce
le
– Fold up cover cap in direction of arrow -B- to unclip.
un
pt
an
d
itte
y li
– Remove spray jet ⇒ page 105 .
rm
ab
pe
ility
– Loosen securing nut of wiper arm by one turn.
ot
wit
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– Fit an M6 nut on top of securing nut.
hole
spec
es, in part or in w
t to the co
– Fit puller - T10369/5- to wiper arm -2-. rrectness of i
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– Fit thrust piece -3- to wiper arm shaft.
nform
ercia
– Screw in bolt -1- until wiper arm has been pulled off the wiper
shaft.
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tion in
– Unscrew nut -4- completely and remove wiper arm.
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– Fit rear window wiper arm, and screw securing nut loosely onto
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wiper arm shaft.
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– Adjust rear window wiper park position ⇒ page 97 . opyri
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3.3.2 Removing and installing wiper arm, ve‐
hicles with rear wing doors
Note
♦ The following section is a description of how to remove and
install the rear window wiper arm on the right rear wing door.
♦ Removal and installation of the rear window wiper arm on the
left rear wing door are carried out in the same way.
Removing
– Move rear window wiper to park position.
96 Rep. gr.92 - Windscreen wash/wipe system
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Unclip cover cap -1- of rear window wiper arm outwards.
– Unscrew hexagon nut -1-.
– Fold rear window wiper arm away from rear window.
– Release rear window wiper arm -2- from rear window wiper
motor shaft by rocking arm back and forth sideways.
Installing
– Fit rear window wiper arm and screw hexagon nut loosely onto
rear window wiper arm shaft.
– Adjust rear window wiper park position ⇒ page 98 .
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⇒ “3.4.1 Adjusting rear window wiper park position, vehicles with
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rear lid”, page 97
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⇒ “3.4.2 Adjusting rear window wiper park position, vehicles with
ot
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rear wing doors”, page 98
h re
hole
spec
3.4.1 Adjusting rear window wiper park posi‐
es, in part or in w
tion, vehicles with rear lid
t to the co
Special tools and workshop equipment required
rrectness of i
♦ Torque wrench - V.A.G 1331-
l purpos
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– Move rear window wiper to park position. Prote AG.
3. Rear window wiper system 97
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
Distance -a- between wiper rubber and lower edge of window
must be 25 ± 5 mm.
AG. Volkswagen AG d
– Adjust park position by moving rear window wiper arm lifksnec‐
wage
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– Tighten securing nut for rear window wiper arm.
ut
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Specified torques
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♦ ⇒ “3.1.1 Assembly overview - rear window wiper system, ve‐
an
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hicles with rear lid”, page 92
erm
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hole
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3.4.2 Adjusting rear window wiper park posi‐
es, in part or in w
t to the co
tion, vehicles with rear wing doors
Special tools and workshop equipment required
rrectness of i
♦ Torque wrench - V.A.G 1331-
l purpos
nf
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orm
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– Move rear window wiper to park position.
Distance -a- between wiper rubber and side edge of window must
be 25 ± 5 mm.
– Adjust park position by moving rear window wiper arm if nec‐
essary.
– Tighten securing nut for rear window wiper arm.
Specified torques
♦ ⇒ “3.1.2 Assembly overview - rear window wiper system, ve‐
hicles with rear wing doors”, page 93
98 Rep. gr.92 - Windscreen wash/wipe system
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
3.5 Removing and installing rear window
wiper motor - V12-
⇒ “3.5.1 Removing and installing rear window wiper motor V12 ,
vehicles with rear lid”, page 99
⇒ “3.5.2 Removing and installing right rear wing door window
wiper motor V93 , vehicles with rear wing doors”, page 100
⇒ “3.5.3 Removing and installing left rear wing door window wiper
motor V92 , vehicles with rear wing doors”, page 101
3.5.1 Removing and installing rear window
wiper motor - V12- , vehicles with rear lid
Special tools and workshop equipment required agen
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Removing
l purpos
– Remove rear window wiper arm ⇒ page 95 .
– Remove lower rear lid trim ⇒ General body repairs, interior;
nf
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Rep. gr. 70 ; Luggage compartment trim; Overview of fitting
rm
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locations – luggage compartment trim .
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– Release and disconnect connector -1- on rear window wiper
or
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motor.
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– Carefully pull rear window wiper motor -4- inwards off rear lid.
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Installing
Installation is carried out in the reverse order. When installing ob‐
serve the following:
3. Rear window wiper system 99
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Electrical system - Edition 04.2019
– Check seal is seated correctly in opening of rear window. Mark
-1- on seal must align with mark -2- on rear window.
Caution
Before inserting rear window wiper motor - V12- , moisten rear
window wiper arm shaft with lubricant polyethylene glycol.
– Install lower rear lid trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Luggage compartment trim; Overview of fitting loca‐
tions – luggage compartment trim .
– Install rear window wiper arm ⇒ page 95 .
Specified torques
♦ ⇒ “3.1.1 Assembly overview - rear window wiper system, ve‐
hicles with rear lid”, page 92
3.5.2 Removing and installing right rear wing
door window wiper motor - V93- , vehi‐ agen
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Removing tho or
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Special tools and workshop equipment required
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♦ Torque wrench - V.A.G 1331-
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– Remove rear window wiper arm ⇒ page 96 .
m
m
atio
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– Remove lower trim of rear wing door ⇒ General body repairs,
o
n in
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interior; Rep. gr. 70 ; Luggage compartment trim; Overview of
thi
te
fitting locations – luggage compartment trim .
sd
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– Release and disconnect connector -1- on rear window wiper
o
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motor.
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– Remove securing bolts -3-.
AG.
– Remove rear window wiper motor -4-.
100 Rep. gr.92 - Windscreen wash/wipe system
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– If necessary, unbolt rear window wiper motor from bracket
-arrows-.
Installing
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Installation is carried
Vol
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serve the following:
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– Make sure that seal -1- is properly seated in installation aper‐
hole
spec
ture of wing door.
es, in part or in w
t to the co
Caution
rrectness of i
Before inserting rear right wing door window wiper motor -
V93- , moisten rear window wiper arm shaft with lubricant
l purpos
polyethylene glycol.
nform
ercia
– Install lower trim of rear wing door ⇒ General body repairs,
m
at
om
interior; Rep. gr. 70 ; Luggage compartment trim; Overview of ion
c
fitting locations – luggage compartment trim .
in t
or
his
ate
– Install rear window wiper arm ⇒ page 96 .
do
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or
Specified torques
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t.
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op
♦ ⇒ “3.1.2 Assembly overview - rear window wiper system, ve‐
C py
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hicles with rear wing doors”, page 93
gh ht
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3.5.3 Removing and installing left rear wing
AG.
door window wiper motor - V92- , vehi‐
cles with rear wing doors
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
Removing
– Remove rear window wiper arms ⇒ page 96 .
– Remove lower trim of rear wing door ⇒ General body repairs,
interior; Rep. gr. 70 ; Luggage compartment trim; Overview of
fitting locations – luggage compartment trim .
– Remove assembly carrier ⇒ General body repairs, exterior;
Rep. gr. 58 ; Door components; Removing and installing as‐
sembly carrier .
3. Rear window wiper system 101
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Electrical system - Edition 04.2019
– Remove hose -1- from window washer system.
– Release and disconnect electrical connector -3-.
– Remove bolts -arrows-.
– Remove rear window wiper motor -2-.
– If necessary, unbolt rear window wiper motor from bracket
-arrows-.
Installing
Installation is carried out in the reverse order. When installing ob‐
serve the following:
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– Make sure that seal -1- is properly seated in installation
auth aper‐ ra
ture of wing door. ss c
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Before inserting the rear left wing door window wiper motor -
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V92- , moisten the wiper arm shaft with polyethylene glycol
h re
lubricant.
hole
spec
es, in part or in w
t to the co
– Install assembly carrier ⇒ General body repairs, exterior; Rep.
gr. 58 ; Door components; Removing and installing assembly
rrectness of i
carrier .
l purpos
– Install lower trim of rear wing door ⇒ General body repairs,
interior; Rep. gr. 70 ; Luggage compartment trim; Overview of
fitting locations – luggage compartment trim .
nform
ercia
– Install rear window wiper arms ⇒ page 96 .
m
a
com
tio
Specified torques
n in
r
te o
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♦ ⇒ “3.1.2 Assembly overview - rear window wiper system, ve‐
s
iva
do
hicles with rear wing doors”, page 93
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rp
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fo
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t.
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Prote AG.
102 Rep. gr.92 - Windscreen wash/wipe system
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
4 Rear window washer system
⇒ “4.1 Assembly overview - rear window washer system”,
page 103
⇒ “4.2 Removing and installing washer fluid reservoir”,
page 105
⇒ “4.3 Removing and installing rear window washer pump”, page
105
⇒ “4.4 Removing and installing spray jet”, page 105
⇒ “4.5 Adjusting spray jet”, page 107
4.1 Assembly overview - rear window wash‐
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⇒ “4.1.1 Assembly overview - rear window washer system,
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⇒ “4.1.2 Assembly overview - rear window washer
ss
au system, vehi‐ ac
cles with rear wing doors”, page 104
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4.1.1 Assembly overview - rear window washer system, vehicles with rear lid
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1 - Spray jet for rear window
, is n
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washer system
hole
spec
❑ Integrated in drive shaft
es, in part or in w
of rear wiper motor
t to the co
❑ Removing and installing
⇒ page 105
rrectness of i
❑ Adjusting ⇒ page 107
l purpos
2 - Connection piece
❑ Connection to rear win‐
nform
ercia
dow spray jet
m
❑ Overview of hose cou‐
a
com
tio
plings for washer fluid
n in
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lines ⇒ page 113
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❑ Coupling point between
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❑ Overview of hose cou‐ op Vo
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plings for washer fluid cted agen
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lines ⇒ page 113
4 - Hose
❑ Hose repair
⇒ page 113
5 - Angled piece
❑ Connection to wind‐
screen and rear window
washer pump
❑ Colour of connection to
windscreen washer sys‐
tem spray jets is black
❑ Colour of connection to
rear window spray jet -
white
❑ Overview of hose cou‐
plings for washer fluid lines ⇒ page 113
4. Rear window washer system 103
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Electrical system - Edition 04.2019
6 - Windscreen and rear window washer pump - V59-
❑ Removing and installing ⇒ page 89
7 - Washer fluid reservoir
❑ The size of the reservoir depends on which headlight washer system is installed.
❑ Removing and installing ⇒ page 86
8 - Filler pipe for washer fluid reservoir
❑ Removing and installing filler pipe ⇒ page 85
4.1.2 Assembly overview - rear window washer system, vehicles with rear wing
doors
1 - Spray jet for rear window
washer system
❑ Right rear wing door
❑ Removing and installing
⇒ page 105
❑ Adjusting ⇒ page 107
2 - Spray jet for rear window
washer system
❑ Left rear wing door
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❑ Removing and installing agen oes
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⇒ page 105 d by gu
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❑ Adjusting ⇒ page 107 utho eo
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3 - T-piece s
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❑ In roof cross member
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wiring harness
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❑ Distribution of washer
ility
ot
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4 - Connection piece
es, in part or in w
t to the co
❑ Coupling point between
body wiring harness and
left door wiring harness.
rrectness of i
❑ Overview of hose cou‐
plings for washer fluid
l purpos
lines ⇒ page 113
5 - Kink protection
nform
ercia
❑ For wiring harness in
m
area between body and
com
tion in
door
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6 - Connection piece
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❑ Connection to left-hand
um
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rear window spray jet
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❑ Overview of hose cou‐
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plings for washer fluid lines ⇒ page 113
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7 - Connection piece
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❑ Connection to right-hand rear window spray jet
❑ Overview of hose couplings for washer fluid lines ⇒ page 113
8 - Connection piece
❑ Coupling point between body wiring harness and right door wiring harness.
❑ Overview of hose couplings for washer fluid lines ⇒ page 113
104 Rep. gr.92 - Windscreen wash/wipe system
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
9 - Kink protection
❑ For wiring harness in area between body and door
10 - Hose
❑ Hose repair ⇒ page 113
11 - Angled piece
❑ Connection to windscreen and rear window washer pump
❑ Colour of connection to windscreen washer system spray jets is black
❑ Colour of connection to rear window spray jets - white
❑ Overview of hose couplings for washer fluid lines ⇒ page 113
12 - Windscreen and rear window washer pump - V59-
❑ Removing and installing ⇒ page 89
13 - Washer fluid reservoir
❑ The size of the reservoir depends on which headlight washer system is installed.
❑ Removing and installing ⇒ page 86
14 - Filler pipe for washer fluid reservoir
❑ Removing and installing filler pipe ⇒ page 85
4.2 Removing and installing washer fluid
reservoir
Note
The washer fluid reservoir (which is the same for the windscreen
and the rear window washer systems) is located in front of the
front left wheel housing. agen
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– Removing and installing washerrisfluid
ed reservoir ⇒ page 86 . ran
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The rear window washer pump supplies both the windscreen and
spec
the rear window washer systems. It is located in the washer fluid
urposes, in part or in wh
reservoir in front of the front left wheel housing.
t to the co
– Removing and installing windscreen and rear window washer
rrectne
pump - V59- ⇒ page 89 .
4.4 Removing and installing spray jet
ss o
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⇒ “4.4.1 Removing and installing rear window spray jet, vehicles
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⇒ “4.4.2 Removing and installing rear window spray jet, vehicles
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spray jet, vehicles with rear lid
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– Allow rear window wiper to adopt park position.
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4. Rear window washer system 105
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Electrical system - Edition 04.2019
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Unclip cover cap -1- of rear window wiper outwards.
– Using suitable long-nose pliers, carefully pull out washer spray
jet in -direction of arrow-.
Installing
Install in the reverse order of removal, observing the following:
– On completion of work, adjust washer jet ⇒ page 107 .
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erm
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spray jet, vehicles with rear wing doors
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Removing
spec
urposes, in part or in wh
– Allow rear window wiper to adopt park position.
t to the co
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
rrectne
– Unclip cover cap -1- of rear window wiper outwards.
ss o
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106 Rep. gr.92 - Windscreen wash/wipe system
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Using suitable long-nose pliers, carefully pull out washer spray
jet.
Installing
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Install in the reverse order of removal. When doing this, notelksthe
wage
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– On completion of work, adjust washer jet ⇒ page
ut 107 .
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es, in part or in w
– Adjusting rear window washer system spray jets ⇒ Mainte‐
t to the co
nance ; Booklet 20.1 ; Descriptions of work .
rrectness of i
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4. Rear window washer system 107
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Electrical system - Edition s04.2019
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⇒ “5.1 Assembly overview - headlight washer system”,
ot p
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page 108
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⇒ “5.2 Removing and installing washer fluid reservoir”, hole
spec
page 109
es, in part or in w
t to the co
⇒ “5.3 Removing and installing headlight washer system pump
V11 ”, page 109
rrectness of i
⇒ “5.4 Removing and installing pop-up cylinder”, page 109
l purpos
⇒ “5.5 Removing and installing washer jets”, page 111
⇒ “5.6 Adjusting spray jets”, page 111
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5.1 Assembly overview - headlight washer system
m
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1 - Washer fluid reservoir
t
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❑ Removing and installing
rp
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⇒ page 86
f
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2 - Connection piece
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❑ Connection to headlight p by
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by
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Prote AG.
❑ Overview of hose cou‐
plings for washer fluid
lines ⇒ page 113
3 - Headlight washer system
pump - V11-
❑ Removing and installing
⇒ page 109
4 - Connection piece
❑ Connection to left spray
jet pop-up cylinder
❑ Overview of hose cou‐
plings for washer fluid
lines ⇒ page 113
5 - Pop-up cylinder for left
spray jet
❑ Removing and installing
pop-up cylinder
⇒ page 109
❑ Removing and installing
spray jets ⇒ page 111
❑ Checking and adjusting
spray jet setting
⇒ page 111
6 - Y-piece
❑ Distribution of washer
fluid to spray jets on
headlight washer sys‐
tem.
7 - Hose
8 - Connection piece
❑ Connection to right spray jet pop-up cylinder
❑ Overview of hose couplings for washer fluid lines ⇒ page 113
108 Rep. gr.92 - Windscreen wash/wipe system
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
9 - Pop-up cylinder for right spray jet
❑ Removing and installing pop-up cylinder ⇒ page 109
❑ Removing and installing spray jets ⇒ page 111
❑ Checking and adjusting spray jet setting ⇒ page 111
10 - Filler pipe for washer fluid reservoir
❑ Removing and installing filler pipe ⇒ page 85
5.2 Removing and installing washer fluid
reservoir
Note agen
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The washer fluid reservoir (which is the same for the window rise and
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the headlight washer systems) is located in front of theut front left
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wheel housing. ss a c
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nl
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– Removing and installing washer fluid reservoir ⇒ page 86 .
itte
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5.3 Removing and installing headlight
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washer system pump - V11-
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Note
t to the co
The headlight washer system pump - V11- is installed in the
rrectness of i
washer fluid reservoir in front of the front left wheel housing.
l purpos
Special tools and workshop equipment required
♦ Drip tray
nf
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orm
Removing
m
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c
– Remove noise insulation ⇒ General body repairs, exterior;
or
thi
Rep. gr. 66 ; Noise insulation; Removing and installing noise
te
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insulation .
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– Switch off ignition and all electrical equipment and then re‐
f
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t.
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move ignition key.
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Cop py
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– Release and disconnect hose connection -4- on headlight
ht
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washer system pump.
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Prote AG.
– Collect leaking fluid in accordance with regulations.
– Release and disconnect connector -2- on headlight washer
system pump.
– Pull pump -3- upwards out of reservoir.
Installing
Install in the reverse order of removal. When doing this, note the
following:
– On completion of installation work, bleed headlight washer
system ⇒ page 111 .
5.4 Removing and installing pop-up cylinder
Removal and installation are described for the left side. Removal
and installation for the right side are similar.
Special tools and workshop equipment required
5. Headlight washer system 109
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Electrical system - Edition 04.2019
♦ Drip tray
Removing
– Switch off ignition and all electrical consumers, and withdraw
ignition key.
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Front bumper; Removing and installing bumper
cover .
– Press release button -1- in direction of arrow -A-.
– Pull water hose -2- off pop-up cylinder -3- in direction of arrow
-B-.
Note
The removal of the cap should be carried out with aid of a second
person.
Caution
Spray jet pop-up cylinders must not be extracted by hand.
Depending on type, a hand-extracted pop-up cylinder can get
stuck during return stroke.
Pushing back pop-up jet piston by hand is not permissible and
can damage pop-up cylinder.
n AG. Volkswagen AG
Eject pop-up cylinder usingoonly
lksw water pressure or air pressure.
age does
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A sticking pop-up cylinder
ris
ed can be brought back to full function‐
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tee
ality by ejecting itauwith
tho water pressure or air pressure. or
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– Working with compressed air, drive pop-up cylinder together
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with cap -1- out of bumper cover and hold it in place.
ility
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– Press cap -1- on both sides out of upper mountings -2- in di‐
, is n
h re
rection of arrow -A-.
hole
spec
– Swing cap -1- in direction of arrow -B- and unclip it from lower
es, in part or in w
t to the co
mountings -3-.
rrectness of i
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Cop py
ht. rig
rig ht
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by lksw
cted agen
Prote AG.
110 Rep. gr.92 - Windscreen wash/wipe system
California 2016 ➤ , Caravelle 2016 ➤. V,oMultivan
AG 2016 ➤ , Transporter 20 ...
lkswagen AG
agen does
Volksw Electrical system
not - Edition 04.2019
y gu
db ara
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– Press release buttons -1- in direction of thoarrow -A-.
r eo
s au ra
c
– Pull pop-up cylinder -2- downwards sout of mounting -3-.
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Installing
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Install in the reverse order of removal, observing the following:
ility
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– Observe the markings distinguishing the pop-up cylinders for
, is n
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left and right.
hole
spec
Ensure that the pop-up cylinder engages audibly when being
es, in part or in w
t to the co
pushed into the mounting.
– When connecting the washer fluid line, ensure that the secur‐
ing clip engages audibly in the connection.
rrectness of i
– Check cover cap is seated correctly on bumper cover.
l purpos
– On completion of installation work, bleed headlight washer
system ⇒ page 111 .
nf
ercia
orm
– Check headlight washer system spray jets and adjust if nec‐
m
atio
m
essary ⇒ page 111 .
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n in
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5.5 Removing and installing washer jets
sd
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Removing
f
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t.
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– Switch off ignition and all electrical consumers, and withdraw
C py
t. rig
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ignition key.
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– Remove pop-up cylinder ⇒ page 109 .
cted agen
Prote AG.
– Pull fasteners in direction of arrow -A-.
– Pull spray jet -1- out of pop-up cylinder -2-.
Installing
Install in the reverse order of removal, observing the following:
Ensure that spray jet engages audibly on both sides when push‐
ing it into pop-up cylinder.
– On completion of installation work, bleed headlight washer
system ⇒ page 111 .
5.6 Adjusting spray jets
Note
The delivered spray jets are preset by the manufacturer so that
there is no need to adjust them following installation.
– Checking adjustment of spray jets ⇒ Maintenance ; Booklet
20.1 ; Descriptions of work .
5.7 Bleeding headlight washer system
To guarantee sound functioning, the headlight washer system
must be bled following assembly work or when operated for the
first time.
– Top up washer fluid reservoir.
– Start engine:
– Switch headlights “ON”.
5. Headlight washer system 111
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Electrical system - Edition 04.2019
– Operate headlight washer system several times (3-5 times, 3
seconds each time).
– If necessary, repeat this bleeding procedure until the pop-up
cylinders and spray jets are functioning correctly.
AG. Volkswagen AG d
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Prote AG.
112 Rep. gr.92 - Windscreen wash/wipe system
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
6 Washer fluid lines
⇒ “6.1 Washer fluid line hose couplings”, page 113
⇒ “6.2 Repairing washer fluid lines”, page 113 AG. Volkswagen AG d
agen oes
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6.1 Washer fluid line hose couplings
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All instructions and information about this chapter: ⇒ Electrical
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ab
system; General information; Rep. gr. 92 ; Hose couplings of
pe
ility
washer fluid lines .
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6.2 Repairing washer fluid lines
spec
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t to the co
Note
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All instructions and information about this chapter: ⇒ Electrical
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system; General information; Rep. gr. 92 ; Hose repair .
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mercia
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com
tion in
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6. Washer fluid lines 113
olkswagen AG
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California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤Vo,lkTransporter
swa 20 ... does
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Electrical system - Edition 04.2019 sed by ara
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94 – Lights, bulbs, switches - exterior
ce
le
un
pt
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1 Headlights
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is n
⇒ “1.1 Assembly overview - headlight”, page 114
h re
ole,
spec
⇒ “1.2 Removing and installing headlight”, page 118
urposes, in part or in wh
t to the co
⇒ “1.3 Adjusting headlights”, page 120
⇒ “1.4 Adjusting headlight installation position”, page 120
rrectne
⇒ “1.5 Removing and installing front turn signal bulb M5 / M7 ”,
page 122
ss o
⇒ “1.6 Installing repair kit for headlight housing”, page 125
cial p
f inform
⇒ “1.7 Converting headlights from driving on right to driving on
mer
left”, page 125
atio
om
n
c
⇒ “1.8 Converting headlights from driving on left to driving on
i
or
n thi
e
right”, page 126
t
sd
iva
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pr
c
⇒ “1.9 Removing and installing headlight range control motor
um
r
fo
V48 / V49 ”, page 127
en
ng
t.
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op py
⇒ “1.10 Removing and installing headlight dipped beam bulb
. C rig
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rig
M29 / M31 ”, page 132 py by
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⇒ “1.11 Removing and installing headlight main beam bulb M30 /
agen
Prote AG.
M32 ”, page 136
⇒ “1.12 Removing and installing side light bulb M1 / M3 ”,
page 139
⇒ “1.13 Removing and installing daytime running light bulb L174 /
L175 ”, page 142
⇒ “1.14 Removing and installing output module for headlight
J667 / J668 ”, page 147
⇒ “1.15 Removing and installing output module 1 for LED head‐
light A27 / A31 ”, page 149
⇒ “1.16 Removing and installing LED headlight fan”, page 151
⇒ “1.17 Fine adjustment of LED modules - LED headlights”, page
152
1.1 Assembly overview - headlight
⇒ “1.1.1 Assembly overview - H4 headlight”, page 114
⇒ “1.1.2 Assembly overview - H7 headlight”, page 116
⇒ “1.1.3 Assembly overview - LED headlights”, page 117
1.1.1 Assembly overview - H4 headlight
114 Rep. gr.94 - Lights, bulbs, switches - exterior
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Electrical system - Edition 04.2019
1 - Headlights
❑ Removing and installing
⇒ page 118
2 - Bolts
❑ Qty. 2
❑ Means of securing
headlight on lock carrier
❑ 4.5 Nm
3 - Daytime running light bulb
❑ Daytime running light
bulb -L174- / -L175-
❑ Removing and installing
⇒ page 142
❑ 12V, BA15s
4 - Housing cover
5 - Headlight range control mo‐
tor
❑ Headlight range control
motors -V48- / -V49-
❑ Removing and installing
⇒ page 127
6 - Housing cover
7 - Housing cover
AG. Volkswagen AG d
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8 - Front turn signal bulb olksw
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❑ Front turn signal bulb - rised
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M5- / -M7- ut
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❑ Removing and installing ss
ce
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⇒ page 122
nl
pt
du
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itte
❑ 12V, PY21W
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9 - Housing cover
ility
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wit
, is n
10 - Headlight dipped beam/main beam bulb
h re
hole
❑ Headlight dipped beam bulb -M29- / -M31-
spec
es, in part or in w
❑ Headlight main beam bulb -M30- / -M32-
❑ Removing and installing ⇒ page 132 t to the co
❑ 12V, H4 60/55W
rrectness of i
11 - Side light bulb
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❑ Side light bulb -M1- / -M3-
❑ Removing and installing ⇒ page 139
nform
ercia
❑ 12V, W5W
m
at
om
12 - Bolts
on
c
in t
or
❑ Qty. 2
his
ate
do
riv
❑ Means of securing headlight on bumper guide profile
p
cum
or
❑ Inner bolt: 2.2 Nm
f
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ng
t.
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❑ Lower bolt: 4.5 Nm ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Headlights 115
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
1.1.2 Assembly overview - H7 headlight
1 - Headlights
❑ Removing and installing
⇒ page 118
2 - Bolts
❑ Qty. 2
❑ Means of securing
headlight on lock carrier
❑ 4.5 Nm
3 - Headlight main beam bulb
❑ Headlight main beam
bulb -M30- / -M32-
❑ Removing and installing
⇒ page 136
❑ 12V, H7 55W
4 - Housing cover
5 - Headlight range control mo‐
tor
❑ Headlight range control
motors -V48- / -V49-
❑ Removing and installing
⇒ page 129
6 - Housing cover
7 - Housing cover
8 - Front turn signal bulb
❑ Front turn signal bulb -
M5- / -M7-
❑ Removing and installing AG. Volkswagen AG d
agen oes
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⇒ page 123 by Vol not
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d
❑ 12V, PWY24W rise nte
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au ra
9 - Headlight dipped beam bulb ss c
ce
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❑ Headlight dipped beam
nl
pt
du
an
bulb -M29- / -M31-
itte
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erm
ab
❑ Removing and installing ⇒ page 133
ility
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❑ 12V, H7 55W
wit
, is n
h re
10 - Housing cover
hole
spec
es, in part or in w
11 - Side light bulb
t to the co
❑ Side light bulb -M1- / -M3-
❑ Removing and installing ⇒ page 140
rrectness of i
❑ 12V, W5W
l purpos
12 - Daytime running light bulb
❑ Daytime running light bulb -L174- / -L175-
nform
ercia
❑ Removing and installing ⇒ page 143
m
at
❑ 12V, W21W
om
ion
c
in t
r
13 - Bolts
o
his
ate
❑ Qty. 2
do
priv
cum
or
❑ Means of securing headlight on bumper guide profile
f
en
ng
t.
yi
❑ Inner bolt: 2.2 Nm
Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
116
Prote AG.
Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
❑ Lower bolt: 4.5 Nm
1.1.3 Assembly overview - LED headlights
1 - Headlights
❑ Removing and installing
⇒ page 118
❑ Removing and installing
headlight range control
unit ⇒ page 215
2 - Bolts
❑ Qty. 2
❑ Means of securing
headlight on lock carrier
❑ 4.5 Nm
3 - Main beam LED module
❑ Headlight main beam
bulb -M30- / -M32-
❑ With reflector
❑ Removing and installing
⇒ page 137 agen
AG. Volkswagen AG d
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❑ Fine adjustment of LED by
Vo gu
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modules ⇒ page 152 rised
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4 - Bolts ss a ra
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❑ Qty. 3 ce
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❑ Means of securing main
itte
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beam LED module in
rm
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pe
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headlight
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❑ 1 Nm
h re
hole
spec
5 - Housing cover
es, in part or in w
❑ Securing bolts for repair
t to the co
cover 1.6 Nm
6 - Headlight range control mo‐
rrectness of i
tor
l purpos
❑ Headlight range control
motors -V48- / -V49-
❑ Removing and installing ⇒ page 129
nform
ercia
7 - Housing cover
m
a
com
tion in
8 - Housing cover
r
te o
thi
❑ Securing bolts for repair cover 1.6 Nm
s
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rp
9 - Bolts
um
fo
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ng
t.
❑ Qty. 2
yi Co
Cop py
❑ Means of securing fan for LED headlight on dipped beam LED module
t. rig
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pyri by
❑ 2.5 Nm
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Prote AG.
10 - LED headlight fan
❑ Behind dipped beam LED module
❑ Removing and installing ⇒ page 151
11 - Dipped beam LED module
❑ Headlight dipped beam bulb -M29- / -M31-
❑ Removing and installing ⇒ page 134
1. Headlights 117
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
❑ Fine adjustment of LED modules ⇒ page 152
12 - Housing cover
13 - Front turn signal bulb
❑ Front turn signal bulb -M5- / -M7-
❑ Removing and installing ⇒ page 124
❑ 12V, H21W
14 - Bolts
❑ Qty. 2
AG. Volkswagen AG d
❑ Means of securing headlight
lksw
agen on bumper guide oesprofile
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o
❑ Inner bolt: 2.2 eNm yV gu
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❑ Lower bolt:ut 4.5 Nm
ho eo
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ss
15 - Output module 1 for left LED headlight
ce
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nl
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❑ Output module 1 for LED headlight -A27- / -A31-
an
itte
y li
❑ Removing and installing ⇒ page 149
erm
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ility
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16 - Bolts
wit
, is n
h re
❑ Qty. 3
hole
spec
❑ Means of securing headlight output module to headlight housing
es, in part or in w
t to the co
❑ 1 Nm
17 - Power output module for headlight
rrectness of i
❑ Output module for headlight -J667- / -J668-
❑ Removing and installing ⇒ page 147
l purpos
18 - Bolts
nform
ercia
❑ Qty. 4
m
❑ Means of securing output module 1 for LED headlight to headlight housing
at
om
io
❑ 1 Nm
n
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1.2 Removing and installing headlight
f
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t.
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Special tools and workshop equipment required t. C rig
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♦ Torque wrench - V.A.G 1410-
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Prote AG.
Note
♦ The procedure for removal and installation is described as an
example for the H4 headlight on the left-hand side.
♦ Removal and installation is basically the same on the right-
hand side and for H7 and LED headlights.
118 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
Removing
– Detach front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Front bumper; Removing and installing bumper
cover .
Note
The bumper cover does not have to be removed completely. For
the headlight in question, it is sufficient to remove the fastenings
at the front and at the sides of the bumper cover. The bumper
cover can then be press downwards carefully until the lower bolt
securing the headlight can be reached.
Caution
Risk of damage to component. n AG. Volkswagen AG do
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♦ Carefully pull off bumper cover. When doing this, make olk ot g
byV ua
sure that the bumper cover is not being deformed ir seor torn.
d ran
tee
tho
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♦ In order to avoid scratches on the surfaces when
ss
au
removing ac
the headlight, mask off the surrounding areas.
ce
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– Separate electrical connector -arrow-.
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t to the co
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nf
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m
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– Unscrew upper bolts -arrows-.
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1. Headlights 119
n AG. Volkswagen AG do
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Vo ot
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d by 2016 ➤ , Transporter 20 ... guara
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Electrical system - Edition 04.2019 tho eo
au ra
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– Unscrews lower bolt -arrow-, while lightly pressing bumper
ce
e
nl
pt
cover downwards.
du
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itte
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erm
– If necessary, unclip radiator fan air guide to gain access to
ab
ility
inner headlight securing bolt ⇒ Power unit; Rep. gr. 19 ; Ra‐
ot p
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diator/radiator fan; Assembly overview - radiator/radiator fan .
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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– Unscrew inner bolt on headlight -arrow-.
nf
ercia
o
– Carefully remove headlight from body aperture, taking care
rm
m
atio
not to damage paintwork on bumper cover when doing so. If
om
necessary, cover bumper cover in area of headlight for pro‐
n in
or c
tection.
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Installing
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Install in the reverse order of removal, observing the following:
t.
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– Insert headlight into holder. When doing this, ensure that guide
t. C rig
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yri
at the side is seated correctly on the wing. p by
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– Check and, if necessary, adjust installation position of head‐ Prote AG.
light to body ⇒ page 120 .
– Tighten all bolts in sequence: top, bottom, inner.
– Perform functional check.
– Check headlight setting and adjust headlight if necessary
⇒ Maintenance ; Booklet 20.1 ; Descriptions of work
Specified torques
♦ ⇒ “1.1.1 Assembly overview - H4 headlight”, page 114
♦ ⇒ “1.1.2 Assembly overview - H7 headlight”, page 116
♦ ⇒ “1.1.3 Assembly overview - LED headlights”, page 117
1.3 Adjusting headlights
Note
Check headlight settings and adjust headlights if necessary
⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .
1.4 Adjusting headlight installation position
Note
♦ The procedure for adjusting the installation position is descri‐
bed as an example for the H4 headlight on the left-hand side.
♦ Adjustment of the installation position is basically the same on
the right-hand side and for H7 and LED headlights.
Special tools and workshop equipment required
120 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1410-
AG. Volkswagen AG d
agen oes
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Procedure
ce
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un
pt
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d
itte
– Detach front bumper cover ⇒ General body repairs, exterior;
y li
erm
ab
Rep. gr. 63 ; Front bumper; Removing and installing bumper
ility
ot p
cover .
wit
is n
h re
ole,
spec
Note
urposes, in part or in wh
t to the co
♦ The bumper cover does not have to be removed completely.
For the headlight in question, it is sufficient to remove the fas‐
tenings at the front and at the sides of the bumper cover. The
rrectne
bumper cover can then be press downwards carefully until the
lower bolt securing the headlight can be reached.
ss o
♦ In the area of the two bolts securing the bumper at the sides,
cial p
f in
it must be ensured that the bolts exposed when the bumper
form
mer
cover is removed do not scratch the wing. Protect this area
atio
with foam padding during assembly work.
om
n
c
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or
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– Loosen upper bolts -arrows-.
t
sd
iva
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fo
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ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Loosen lower bolt -arrow-, while lightly pressing bumper cover
downwards.
1. Headlights 121
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Electrical system - Edition 04.2019
– Loosen inner bolt on headlight -arrow-.
– Place all screws in holes but do not tighten firmly yet.
– Using upper adjustment bushes -A- and lower bolt, adjust po‐
sition of headlight in relation to body, while ensuring that gaps
are even. n AG. Volkswagen AG age does
ksw not
– Tighten all bolts in sequence: top, bottom,
by inner.
Vol gu
ara
ed nte
ris
– Close bonnet. tho eo
s au ra
c
– Check position of headlight in relation
s to body and, if neces‐
ce
e
sary, adjust again with aid of adjustment bushes.
nl
pt
du
an
itte
y li
– Perform functional check.
erm
ab
ility
ot p
– Check headlight setting and adjust headlight if necessary
wit
, is n
⇒ Maintenance ; Booklet 20.1 ; Descriptions of work
h re
hole
Specified torques
spec
es, in part or in w
t to the co
♦ ⇒ “1.1.1 Assembly overview - H4 headlight”, page 114
♦ ⇒ “1.1.2 Assembly overview - H7 headlight”, page 116
rrectness of i
♦ ⇒ “1.1.3 Assembly overview - LED headlights”, page 117
l purpos
1.5 Removing and installing front turn signal
bulb -M5- / -M7- nf
ercia
orm
m
atio
⇒ “1.5.1 Removing and installing front turn signal bulb M5 / M7 ,
om
H4 headlight”, page 122
n in
or c
thi
e
⇒ “1.5.2 Removing and installing front turn signal bulb M5 / M7 ,
t
sd
iva
H7 headlight”, page 123
r
rp
cu
o
m
f
en
ng
⇒ “1.5.3 Removing and installing front turn signal bulb M5 / M7 ,
t.
yi Co
op
LED headlights”, page 124 C py
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1.5.1 Removing and installing front turn signal
p by
o Vo
by c lksw
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bulb -M5- / -M7- , H4 headlight
Prote AG.
Removing
– Pull off housing cover -4- from headlight.
122 Rep. gr.94 - Lights, bulbs, switches - exterior
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Electrical system - Edition 04.2019
– Turn grip piece -1- in direction of -arrow- and pull out bulb from
reflector.
– Push bulb -1- into holder and, at same time, turn it anti-clock‐
wise and pull it out from bulb holder -2-.
Front turn signal bulb -M5- / -M7- : 12V, PY21W
Installing
Install in the reverse order of removal, observing the following:
Caution
Risk of damage to the headlight.
♦ Do not touch the glass part of the bulb with bare fingers.
Fingers leave traces of grease on the glass bulb, which
evaporate when the bulb is switched on and cause the
glass bulb to cloud over.
♦ Wear e.g. clean fabric gloves when inserting bulbs.
. Volkswagen AG
gen AG
♦ Make sure the housing ksw cover is correctly seatednowhen in‐
a oes d
Vol t gu
stalling. The ingress
ed by of water will cause permanent adam‐
ra
age to the thheadlight.
or
is nte
eo
au ra
c
ss
ce
le
un
– Perform functional check.
pt
an
d
itte
y li
erm
ab
1.5.2 Removing and installing front turn signal
ility
ot p
wit
bulb -M5- / -M7- , H7 headlight
is n
h re
ole,
spec
Removing
urposes, in part or in wh
t to the co
– Pull off housing cover -4- from headlight.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
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t.
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Cop py
t. rig
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Vo
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by c lksw
cted agen
Prote AG.
1. Headlights 123
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Electrical system - Edition 04.2019
– Pull out grip piece -1- from reflector together with bulb.
– Pull out bulb -1- in straight line from bulb holder -2-.
Front turn signal bulb -M5- / -M7- : 12V, PWY24W
Installing
Install in the reverse order of removal, observing the following:
Caution
Risk of damage to the headlight.
. Volkswagen AG
gen AG
♦ Do not touch the glass part of the bulb
ksw with bare fingers.
a does
not
Vol
Fingers leave traces of grease d on the glass bulb, which
by gu
ara
evaporate when the bulbthis ise
or switched on and cause the
nte
eo
glass bulb to cloud over.
sa
u ra
c
s
♦ Wear e.g. clean fabric gloves when inserting bulbs.
ce
le
un
pt
an
d
itte
♦ Make sure the housing cover is correctly seated when in‐
y li
rm
ab
stalling. The ingress of water will cause permanent dam‐
pe
ility
age to the headlight.
ot
wit
, is n
h re
hole
spec
– Perform functional check.
es, in part or in w
t to the co
1.5.3 Removing and installing front turn signal
bulb -M5- / -M7- , LED headlights
rrectness of i
l purpos
Removing
– Remove headlight ⇒ page 118 .
nform
ercia
– Pull off housing cover -6- from headlight.
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
124 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Turn grip piece -1- in direction of -arrow- and pull out bulb from
reflector.
– Separate electrical connector -1- on front left turn signal bulb
and its holder -2-.
– Remove front turn signal bulb -M5- / -M7- : 12V, H21W from
holder -2-.
Installing
Install in the reverse order of removal, observing the following:
Caution
Risk of damage to the headlight.
♦ Do not touch the glass part of the bulb with bare fingers.
Fingers leave traces of grease on the glass bulb, which
evaporate when the bulb is switched on and cause the
glass bulb to cloud over.
♦ Wear e.g. clean fabric gloves when inserting bulbs.
♦ Make sure the housing cover is correctly seated when in‐
stalling. The ingress of water will cause permanent dam‐
age to the headlight.
AG. Volkswagen AG d
agen oes
lksw not
– Perform functional check. by
Vo gu
ara
ed
is nte
Specified torques ut
hor eo
ra
s a c
♦ ⇒ “1.1.3 Assembly overview - LED headlights”, page 117 s
ce
le
un
pt
an
d
itte
1.6 Installing repair kit for headlight housing
y li
rm
ab
pe
ility
No information on this subject was available for this chapter at the
ot
wit
, is n
time of publication.
h re
hole
spec
1.7 Converting headlights from driving on
es, in part or in w
t to the co
right to driving on left
⇒ “1.7.1 Converting headlights from driving on right to driving on
rrectness of i
left, H4 headlights”, page 125
l purpos
⇒ “1.7.2 Converting headlights from driving on right to driving on
left, H7 headlights”, page 126
nform
ercia
⇒ “1.7.3 Converting headlights from driving on right to driving on
left, LED headlights”, page 126
m
a
com
tio
1.7.1 Converting headlights from driving on
n in
r
te o
thi
right to driving on left, H4 headlights
s
iva
do
r
rp
cum
If an RHD vehicle is driven in a left-traffic country, or vice versa,
fo
en
ng
the headlights do not need to be adapted in any way.
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
125
cted agen
Prote
1. Headlights
AG.
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Electrical system - Edition 04.2019
1.7.2 Converting headlights from driving on
right to driving on left, H7 headlights
n AG . Volkswagen AG
If an RHD vehicle is driven in a left-traffic country, orksvice
wage versa, does
not
l
the headlights do not need to be adapted in anybyway.V o gu
ara
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ris
1.7.3 Converting headlights from driving on au
tho eo
ra
right to driving on left, LED headlights
ss c
ce
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un
pt
an
d
If a right-hand drive vehicle is driven in a left-hand drive country, itte
y li
or vice versa, the headlights must be converted. This is necessary
erm
ab
in order to avoid dazzling oncoming traffic with the asymmetric
ility
ot p
low beam headlights.
wit
is n
h re
ole,
spec
urposes, in part or in wh
Note
t to the co
♦ The adjustment for driving on the left to driving on the right or
vice versa (travel mode) is carried out in the dash panel insert
rrectne
using the menu.
♦ It is only permissible to make use of the headlight converter
ss
for a short period of time. When permanently driving in the
o
cial p
f i
respective country during a longer period of time, suitable
nform
headlights need to be installed according to valid specifica‐
mer
tions.
atio
om
n
c
i
or
n thi
– Call up main menu in dash panel insert ⇒ Operating instruc‐
te
sd
a
tions .
iv
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– Call up “Settings” menu.
en
ng
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– Call up “Light & visibility” sub-menu option.
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– Activate or deactivate “Travel mode” menu item to switch trav‐
op Vo
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el mode on or off.
cted agen
Prote AG.
1.8 Converting headlights from driving on
left to driving on right
⇒ “1.8.1 Converting headlights from driving on left to driving on
right, H4 headlights”, page 126
⇒ “1.8.2 Converting headlights from driving on left to driving on
right, H7 headlights”, page 126
⇒ “1.8.3 Converting headlights from driving on left to driving on
right, LED headlights”, page 126
1.8.1 Converting headlights from driving on
left to driving on right, H4 headlights
If an RHD vehicle is driven in a left-traffic country, or vice versa,
the headlights do not need to be adapted in any way.
1.8.2 Converting headlights from driving on
left to driving on right, H7 headlights
If an RHD vehicle is driven in a left-traffic country, or vice versa,
the headlights do not need to be adapted in any way.
1.8.3 Converting headlights from driving on
left to driving on right, LED headlights
If a right-hand drive vehicle is driven in a left-hand drive country,
or vice versa, the headlights must be converted. This is necessary
in order to avoid dazzling oncoming traffic with the asymmetric
low beam headlights.
126 Rep. gr.94 - Lights, bulbs, switches - exterior
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Electrical system - Edition 04.2019
Note
♦ The adjustment for driving on the left to driving on the right or
vice versa (travel mode) is carried out in the dash panel insert
using the menu.
♦ It is only permissible to make use of the headlight converter
for a short period of time. When permanently driving in the
respective country during a longer period of time, suitable
headlights need to be installed according to valid specifica‐
tions.
– Call up main menu in dash panel insert ⇒ Operating instruc‐
tions .
– Call up “Settings” menu.
– Call up “Light & visibility” sub-menu option.
– Activate or deactivate “Travel mode” menu item to switch trav‐
el mode on or off. wage
n AG. Volkswagen AG do
e ks s no
Vol t gu
1.9 Removing and installing headlight range ris
ed by ara
nte
control motor -V48- / -V49- tho eo
au ra
ss c
ce
⇒ “1.9.1 Removing and installing headlight range control motor
e
nl
pt
du
V48 / V49 , H4 headlights”, page 127
an
itte
y li
erm
ab
⇒ “1.9.2 Removing and installing headlight range control motor
ility
ot p
V48 / V49 , H7 headlights”, page 129
wit
, is n
h re
⇒ “1.9.3 Removing and installing headlight range control motor
hole
V48 / V49 , LED headlights”, page 129
spec
es, in part or in w
t to the co
1.9.1 Removing and installing headlight range
control motor -V48- / -V49- , H4 head‐
rrectness of i
lights
l purpos
Removing
– Remove headlight ⇒ page 118 .
nf
ercia
– Pull off housing cover -2- from headlight. orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
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o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Headlights 127
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Electrical system - Edition 04.2019
– Pull vertical adjuster -1- upwards out of headlight.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
tho eo
au ra
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ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
– Turn headlight range control motor -2- to stop in direction of
h re
arrow -A- to release it.
ole,
spec
urposes, in part or in wh
– Pull headlight range control motor -2- towards rear out of
t to the co
headlight until connector is accessible.
– Disconnect electrical connector -1-.
rrectne
– Pull out ball head on headlight range control motor -1- from
mounting on reflector.
ss
Installing
o
cial p
f inform
Install in the reverse order of removal, observing the following:
mer
atio
om
n
c
Caution
i
or
n thi
te
sd
va
Risk of damage to the headlight.
i
o
pr
cum
r
fo
en
♦ Make sure the housing cover is correctly seated when in‐
ng
t.
yi Co
stalling. The ingress of water will cause permanent dam‐ t. Cop py
age to the headlight.
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– While pressing in headlight range control motor , fit electrical
connector.
– Release wire clasp and remove housing cover -1- from head‐
light.
– Reach through opening behind housing cover -1- then pull
back and hold reflector.
– Press headlight range control motor into mounting on reflector
until it can be heard to engage.
128 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Turn headlight range control motor -2- to stop in direction of
arrow -B- to engage it.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
– Install vertical adjuster -1-.
es, in part or in w
t to the co
– Perform functional check.
– Check headlight settings, and adjust headlights if necessary
⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
c
1.9.2 Removing and installing headlight range
um
for
en
ng
control motor -V48- / -V49- , H7 head‐
t.
yi Co
Cop py
lights
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ The procedure for removal and installation of the headlight
range control motor -V48- / -V49- in the H7 headlight is the
same as that for the H4 headlight.
♦ Removing and installing headlight range control motor -V48- /
-V49- , H4 headlights ⇒ page 127 .
1.9.3 Removing and installing headlight range
control motor -V48- / -V49- , LED head‐
lights
Special tools and workshop equipment required
♦ Torque screwdriver - VAS 6494-
1. Headlights 129
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Electrical system - Edition 04.2019
♦ ESD workplace - VAS 6613-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
Note
itte
y li
erm
ab
ility
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Removal and installation are described for the left side. The re‐
wit
moval and installation procedure for the right-hand side is basi‐
, is n
h re
cally the same.
hole
spec
es, in part or in w
t to the co
Caution
rrectness of i
Work on the LED control motor may only be performed in an
ESD workplace.
l purpos
nf
ercia
Removing
orm
m
– Remove headlight ⇒ page 118 .
atio
om
n in
c
– Pull off cap -2- from headlight housing.
or
thi
te
sd
a
– Remove housing cover from main beam LED module to gain
iv
o
r
rp
cu
access to control motor ball head ⇒ page 137 .
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Separate electrical connector -1- from control motor -2-.
– To release, turn control motor -2- in direction of arrow -B- as
far as stop.
130 Rep. gr.94 - Lights, bulbs, switches - exterior
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Electrical system - Edition 04.2019
– Unscrew bolt -arrow- and remove adjuster -1- with shaft.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
– Push ball head on control motor
horis
-1- upwards as far as it will nte
eo
go. aut ra
ss c
ce
le
– Tilt control motor and pull out sideways from guide -2-.
un
pt
an
d
itte
Installing
y li
erm
ab
ility
Install in the reverse order of removal, observing the following:
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
– Push control motor -1- into guide -2-.
ss
– Push ball head on control motor -1- downwards as far as it will
o
cial p
f
go and install adjuster.
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
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pyri by
Vo
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by c lksw
cted agen
– To engage, turn control motor -2- in direction of arrow -B- as Prote AG.
far as it will go.
– Fit electrical connector -1- on control motor -2-.
1. Headlights 131
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Electrical system - Edition 04.2019
– Install adjuster -1- with shaft.
Caution
Risk of damage to the headlight.
♦ Make sure the housing cover is correctly seated when in‐
stalling. The ingress of water will cause permanent dam‐
age to the headlight.
– Perform functional check.
– Install new housing cover on main beam LED module
⇒ page 137 .
– Check headlight setting and adjust headlight if necessary
⇒ Maintenance ; Booklet 20.1 ; Descriptions of work
Specified torques
♦ ⇒ “1.1.3 Assembly overview - LED headlights”, page 117
1.10 Removing and installing headlight dip‐
ped beam bulb -M29- / -M31-
⇒ “1.10.1 Removing and installing headlight dipped beam bulb
M29 / M31 , H4 headlight”, page 132
⇒ “1.10.2 Removing and installing headlight dipped beam bulb
M29 / M31 , H7 headlight”, page 133
⇒ “1.10.3 Removing and installing headlight dipped beam bulb
M29 / M31 , LED headlights”, page 134
1.10.1 Removing and installing headlight dip‐
ped beam bulb -M29- / -M31- , H4 head‐
light olkswa n AG. V gen AG
wage does
Removing Volks not
gu
by ara
ed
– Release wire clasp and remove
horis housing cover -1- from head‐ nte
eo
light. aut ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co
132
by lksw
cted agen
Rep. gr.94 - Lights, bulbs, switches - exterior Prote AG.
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
AG. Volkswagen AG d
sw agen
Electrical system - Edition
oes 04.2019
olk no t gu
yV
db ara
– Disconnect electrical connector -3-. rise nte
tho eo
au ra
– Release wire clasp -1- and fold down. ss c
ce
e
nl
pt
– Remove bulb -2- from reflector.
du
an
itte
y li
Headlight dipped beam bulb -M29- / -M31- : 12V, H4 60/55W
erm
ab
ility
ot p
Installing
wit
, is n
h re
Install in the reverse order of removal, observing the following:
hole
spec
es, in part or in w
t to the co
Caution
Risk of damage to the headlight.
rrectness of i
♦ Do not touch the glass part of the bulb with bare fingers.
Fingers leave traces of grease on the glass bulb, which l purpos
evaporate when the bulb is switched on and cause the
glass bulb to cloud over.
nf
ercia
orm
♦ Wear e.g. clean fabric gloves when inserting bulbs.
m
atio
om
n in
♦ Make sure the housing cover is correctly seated when in‐
or c
thi
stalling. The ingress of water will cause permanent dam‐
te
sd
a
age to the headlight.
iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
– Perform functional check. C py
t. rig
gh ht
yri by
– Check headlight setting and adjust headlight if necessary cop Vo
by lksw
⇒ Maintenance ; Booklet 20.1 ; Descriptions of work cted agen
Prote AG.
1.10.2 Removing and installing headlight dip‐
ped beam bulb -M29- / -M31- , H7 head‐
light
Removing
– Release wire clasp and remove housing cover -1- from head‐
light.
1. Headlights 133
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Electrical system - Edition 04.2019
– Tilt bulb -1- sideways to release it, and pull it out of reflector.
– Pull bulb -1- off connector.
Headlight dipped beam bulb -M29- / -M31- : 12V, H7 55W
Installing
Install in the reverse order of removal, observing the following:
Caution
Risk of damage to the headlight.
♦ Do not touch the glass part of the bulb with bare fingers.
Fingers leave traces of grease on the glass bulb, which
evaporate when the bulb is switched on and cause the
glass bulb to cloud over.
♦ Wear e.g. clean fabric gloves when inserting bulbs.
♦ Make sure the housing cover is correctly seated when in‐
stalling. The ingress of water will cause permanent dam‐
age to the headlight.
– Perform functional check.
– Check headlight setting and aadjust
gen AG headlightnifAG
. Volkswage necessary
does
⇒ Maintenance ; Booklet
V olk20.1
sw ; Descriptions of work not
g y ua
db ran
rise tee
tho
1.10.3 Removing and installing headlight dip‐
s au
or
ac
ped beam bulb -M29- / -M31- , LED
s
ce
le
un
pt
headlights
an
d
itte
y li
rm
ab
Special tools and workshop equipment required
pe
ility
ot
wit
, is n
♦ Torque screwdriver - VAS 6494-
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
♦ ESD workplace - VAS 6613-
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
134 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
Note
♦ The dipped beam function in the LED headlight is not per‐
formed by a conventional bulb but an LED module instead.
♦ Removal and installation are described for the left side. The
removal and installation procedure for the right-hand side is
basically the same.
Caution AG. Volkswagen AG d
agen oes
olksw not
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Work on the LED module mustedbe by performed only at an ESD gu
ara
workplace. horis nte
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aut ra
ss c
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le
un
Removing
pt
an
d
itte
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– Remove headlight ⇒ page 118 .
rm
ab
pe
ility
– Using a hammer, carefully detach housing cover -1- around
ot
wit
, is n
engineered break line -2-. Preferably, strike on the corners of
h re
hole
the cover when doing this to prevent it from breaking.
spec
es, in part or in w
– Remove housing cover -1- from headlight.
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
– Disconnect electrical connector -2-.
r
te o
thi
s
iva
– Unscrew bolts -arrows- of LED module.
do
r
rp
cum
fo
– Guide main beam LED module -1- backwards out of headlight.
en
ng
t.
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op
Installing C py
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rig ht
by
Install in the reverse order of removal, observing the following: copy Vo
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cted agen
Prote AG.
– Insert LED module and, when doing this, ensure that centring
pins on LED module are correctly positioned in mountings
-arrows-.
– Connect electrical connector.
Caution
Risk of damage to the headlight.
♦ Make sure the housing cover is correctly seated when in‐
stalling. The ingress of water will cause permanent dam‐
age to the headlight.
1. Headlights 135
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Electrical system - Edition 04.2019
– Position new housing cover -1- onto headlight.
– Screw in and tighten bolts -arrows-.
– Calibrate LED modules ⇒ page 152 .
– Perform functional check.
– Check headlight setting and adjust headlight if necessary
⇒ Maintenance ; Booklet 20.1 ; Descriptions of work
Specified torques
♦ ⇒ “1.1.3 Assembly overview - LED headlights”, page 117
n AG. Volkswagen AG do
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1.11 Removing and installing headlight main o tee
th or
au ac
beam bulb -M30- / -M32- ss
ce
e
nl
pt
du
an
⇒ “1.11.1 Removing and installing headlight main beam bulb itte
y li
M30 / M32 , H4 headlight”, page 136
erm
ab
ility
ot p
⇒ “1.11.2 Removing and installing headlight main beam bulb
wit
, is n
M30 / M32 , H7 headlight”, page 136
h re
hole
spec
⇒ “1.11.3 Removing and installing headlight main beam bulb
es, in part or in w
M30 / M32 , LED headlights”, page 137
t to the co
1.11.1 Removing and installing headlight main
beam bulb -M30- / -M32- , H4 headlight
rrectness of i
l purpos
Note
nf
ercia
or
♦ In H4 headlights, the main beam is generated by the dipped
m
m
atio
beam bulb -M29- / -M31- .
om
n in
or c
♦ Removing and installing headlight dipped beam bulb -M29- /
thi
te
-M31- ⇒ page 132 .
sd
iva
o
r
rp
cu
o
m
f
en
ng
1.11.2 Removing and installing headlight main
t.
yi Co
op py
beam bulb -M30- / -M32- , H7 headlight
t. C rig
gh ht
pyri by
Vo
co
Removing
by lksw
cted agen
Prote AG.
– Pull off housing cover -3- from headlight.
136 Rep. gr.94 - Lights, bulbs, switches - exterior
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Electrical system - Edition 04.2019
– Tilt bulb -1- sideways to release it, and pull it out of reflector.
– Pull bulb -1- off connector.
Headlight main beam bulb -M30- / -M32- : 12V, H7 55W
Installing
Install in the reverse order of removal, observing the following:
Caution
Risk of damage to the headlight.
♦ Do not touch the glass part of the bulb with bare fingers.
Fingers leave traces of grease on the glass bulb, which
evaporate when the bulb is switched on and cause the
glass bulb to cloud over. AG. Volkswagen AG d
agen oes
ksw n ol ot g
yV
♦ Wear e.g. clean fabric gloves when inserting ibulbs.
se
db ua
ran
r tee
ho
♦ Make sure the housing cover is correctlys seated
au
t
when in‐ or
ac
stalling. The ingress of water will cause spermanent dam‐
ce
e
age to the headlight.
nl
pt
du
an
itte
y li
erm
ab
ility
– Perform functional check.
ot p
wit
, is n
– Check headlight setting and adjust headlight if necessary
h re
hole
⇒ Maintenance ; Booklet 20.1 ; Descriptions of work
spec
es, in part or in w
t to the co
1.11.3 Removing and installing headlight main
beam bulb -M30- / -M32- , LED head‐
rrectness of i
lights
l purpos
Special tools and workshop equipment required
♦ Torque screwdriver - VAS 6494-
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
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Prote AG.
♦ Torque wrench 50-100Ncm - VAS 6253A-
1. Headlights 137
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Electrical system - Edition 04.2019
♦ ESD workplace - VAS 6613-
AG. Volkswagen AG d
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olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
Note
ole,
spec
urposes, in part or in wh
♦ The main beam in the LED headlight is not generated by a
t to the co
conventional bulb but an LED module instead.
♦ Removal and installation are described for the left side. The
rrectne
removal and installation procedure for the right-hand side is
basically the same.
ss o
cial p
f in
Caution
form
mer
atio
m
Work on the LED module must be performed only at an ESD
o
n
c
workplace. i
or
n thi
te
sd
iva
o
pr
cum
r
Removing
fo
en
ng
t.
yi Co
– Remove headlight ⇒ page 118 . Cop py
t. rig
gh ht
yri
– Using a hammer, carefully detach housing cover -1- around p by
o Vo
by c
engineered break line -2-. Preferably, strike on the corners of
lksw
cted agen
Prote
the cover when doing this to prevent it from breaking.
AG.
– Remove housing cover -1- from headlight.
– Remove output module for headlight -J667- / -J668- -3- to gain
access to electrical connector ⇒ page 147 .
– Unscrew three bolts -arrows- of LED module -1-.
– Guide main beam LED module -1- backwards out of headlight
and separate electrical connector.
Installing
Install in the reverse order of removal, observing the following:
138 Rep. gr.94 - Lights, bulbs, switches - exterior
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Electrical system - Edition 04.2019
– Insert LED module and, when doing this, ensure that LED
module is correctly positioned on centring pins -arrows-.
– Join electrical connector when inserting.
– Install output module for headlight -J667- / -J668-
⇒ page 147 .
Caution
Risk of damage to the headlight.
♦ Make sure the housing cover is correctly seated when in‐
stalling. The ingress of water will cause permanent dam‐
age to the headlight.
– Position new housing cover -1- onto headlight.
– Screw in and tighten bolts -arrows-.
– Calibrate LED modules ⇒ page 152 .
– Perform functional check.
– Check headlight setting and adjust headlight if necessary
⇒ Maintenance ; Booklet 20.1 ; Descriptions of work
Specified torques
♦ ⇒ “1.1.3 Assembly overview - LED headlights”, page 117
. Volkswage n AG n AG d
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Volks not
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1.12 au
tho
Removing and installing side light bulb - eo
ra
c
ss
M1- / -M3-
ce
le
un
pt
an
d
⇒ “1.12.1 Removing and installing side light bulb M1 / M3 , H4
itte
y li
headlight”, page 139
rm
ab
pe
ility
ot
⇒ “1.12.2 Removing and installing side light bulb M1 / M3 , H7
wit
, is n
headlight”, page 140
h re
hole
spec
⇒ “1.12.3 Removing and installing side light bulb M1 / M3 , LED
es, in part or in w
headlights”, page 141
t to the co
1.12.1 Removing and installing side light bulb -
M1- / -M3- , H4 headlight
rrectness of i
l purpos
Removing
– Release wire clasp and remove housing cover -1- from head‐
nform
ercia
light.
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Headlights 139
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Electrical system - Edition 04.2019
– Push button on connector -1- and pull out side light bulb with
holder from reflector.
– Pull out side light bulb -1- from holder -2-.
Side light bulb -M1- / -M3- : 12V, W5W
AG. Volkswagen AG d
agen oes
Installing olksw not
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d b ara
Install in the reverse order of removal, observing the following: rise nte
tho eo
au ra
ss c
ce
Caution
le
un
pt
an
d
itte
y li
Risk of damage to the headlight.
rm
ab
pe
ility
♦ Do not touch the glass part of the bulb with bare fingers.
ot
wit
, is n
Fingers leave traces of grease on the glass bulb, which
h re
hole
evaporate when the bulb is switched on and cause the
spec
glass bulb to cloud over.
es, in part or in w
t to the co
♦ Wear e.g. clean fabric gloves when inserting bulbs.
♦ Make sure the housing cover is correctly seated when in‐
rrectness of i
stalling. The ingress of water will cause permanent dam‐
age to the headlight.
l purpos
nform
ercia
– Perform functional check.
m
a
com
ti
1.12.2 Removing and installing side light bulb -
on in
r
te o
M1- / -M3- , H7 headlight
thi
s
iva
do
r
rp
Removing cum
fo
en
ng
t.
yi
– Release wire clasp and remove housing cover -1- from head‐
Co
op py
light. t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
140 Rep. gr.94 - Lights, bulbs, switches - exterior
AG. Volkswagen
Californiaksw2016 ➤ , Caravelle 2016
agen AG do
es n➤ , Multivan 2016 ➤ , Transporter 20 ...
y Vol ot g
ua Electrical system - Edition 04.2019
dbe ra
ris nte
tho eo
– Pull out side lights bulb
au with holder -1- from reflector. ra
c
s
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
– Pull out side light bulb -1- in straight line from holder -2-.
ss o
cial p
f
Side light bulb -M1- / -M3- : 12V, W5W
inform
mer
Installing
atio
om
Install in the reverse order of removal, observing the following:
n
c
i
or
n thi
te
sd
va
Caution
i
o
pr
cum
r
fo
en
ng
t.
Risk of damage to the headlight.
yi Co
Cop py
t. rig
♦ Do not touch the glass part of the bulb with bare fingers.
gh ht
pyri by
Fingers leave traces of grease on the glass bulb, which
o Vo
by c lksw
cted
evaporate when the bulb is switched on and cause the
agen
Prote AG.
glass bulb to cloud over.
♦ Wear e.g. clean fabric gloves when inserting bulbs.
♦ Make sure the housing cover is correctly seated when in‐
stalling. The ingress of water will cause permanent dam‐
age to the headlight.
– Perform functional check.
1.12.3 Removing and installing side light bulb -
M1- / -M3- , LED headlights
Note
♦ The side light function on LED headlights is performed by the
LED module for daytime running lights.
♦ The LED module for daytime running lights cannot be replaced
individually. In the event of damage, the headlight must be re‐
newed ⇒ page 118 .
1. Headlights 141
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1.13 Removing and installing daytime run‐
ning light bulb -L174- / -L175-
⇒ “1.13.1 Removing and installing daytime running light bulb
L174 / L175 , H4 headlight”, page 142
⇒ “1.13.2 Removing and installing daytime running light bulb
L174 / L175 , H7 headlights, bulb holder with electrical wiring”,
page 143
⇒ “1.13.3 Removing and installing daytime running light bulb
L174 / L175 , H7 headlights, bulb holder without electrical wiring”,
page 145
⇒ “1.13.4 Removing and installing daytime running light bulb
L174 / L175 , LED headlights”, page 147
1.13.1 Removing and installing daytime run‐
ning light bulbge-L174- / -L175- , H4 head‐
n AG. Volkswagen AG do
light by Volkswa es n
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ed ran
Removing ris tee
tho or
au ac
– Pull off housing
ss cover -3- from headlight. ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Release connector -1- in direction of -arrow- and pull out from
reflector.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
142 Rep. gr.94 - Lights, bulbs, switches - exterior
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Electrical system - Edition 04.2019
– Push daytime running light bulb -1- into holder and, at same
time, turn it anti-clockwise and pull it out from bulb holder -2-.
Bulb for daytime running light -L174- / -L175- : 12V, BA15s
Installing
Install in the reverse order of removal, observing the following:
Caution
Risk of damage to the headlight.
♦ Do not touch the glass part of the bulb with bare fingers.
Fingers leave traces of grease on the glass bulb, which
evaporate when the bulb is switched on and cause the
glass bulb to cloud over.
♦ Wear e.g. clean fabric gloves when inserting bulbs.
♦ Make sure the housing cover is correctly seated when in‐
stalling. The ingress of water will cause permanent dam‐
age to the headlight.
– Perform functional check.
– Check headlight setting and adjust headlight if necessary
⇒ Maintenance ; Booklet 20.1 ; Descriptions of work
1.13.2 Removing and installing daytime run‐
ning light bulb -L174- / -L175- , H7 head‐
lights, bulb holder with
swa
electrical
gen AG
. Volkswawiring
gen AG
does
k not
Vol gu
Special tools and workshop equipment
se
db
y
required ara
nte
ri
ho eo
♦ Spring-type clip pliers - VAS
ut 5024/A- or hose clip pliers - VAS ra
sa c
6340- s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
Right headlight
nf
ercia
orm
– Pull off electrical connector -1-.
m
atio
om
n in
– Release hose clip -2- and pull off intake hose.
or c
thi
te
– Open spring retainers -arrows-.
sd
iva
o
r
rp
cu
– Remove air filter upper part.
o
m
f
en
ng
t.
yi Co
Continued for both headlights Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Headlights 143
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Electrical system - Edition 04.2019
– Remove housing cover -1-.
– Release and pull out bulb holder -1- in direction of -arrow-. AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Pull daytime running light bulb -L174- / -L175- -1- out of bulb
holder -2-.
rrectness of i
Installing
l purpos
Install in the reverse order of removal, observing the following:
nform
ercia
Caution
m
a
com
tio
Risk of damage to the headlight.
n in
r
te o
thi
♦ Do not touch the glass part of the bulb with bare fingers.
s
iva
do
r
rp
cum
♦ Wear e.g. clean fabric gloves when inserting bulbs.
fo
en
ng
t.
yi
♦ Make sure the housing cover is correctly seated when in‐
Co
Cop py
stalling.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Right headlight
– Install air filter upper part. Ensure air filter insert is seated cor‐
rectly in housing when doing this.
– Check that seal is in full contact.
– Lock spring retainers -arrows-.
– Attach air intake hose.
– Secure hose clip -2- on intake hose.
– Fit electrical wiring connection -1-.
Continued for both headlights
– Perform functional check.
– Check headlight setting and adjust headlight if necessary
⇒ Maintenance ; Booklet 20.1 ; Descriptions of work
144 Rep. gr.94 - Lights, bulbs, switches - exterior
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Electrical system - Edition 04.2019
1.13.3 Removing and installing daytime run‐
ning light bulb -L174- / -L175- , H7 head‐
lights, bulb holder without electrical
wiring
Special tools and workshop equipment required
♦ Wiring harness repair set - VAS 1978 B-
Removing
– Remove headlight ⇒ page 118 .
– Remove housing cover -1-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
– Release and pull out bulb holder
ise
d b -1- in direction of -arrow-. ara
nte
or eo
th
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
Installing
Install in the reverse order of removal, observing the following:
ss o
cial p
The work steps described below must be performed on both
f in
headlights.
form
mer
atio
– Open cable tie -1-.
om
n
c
i
or
– Guide out electrical wiring -2-.
thi
te
sd
va
– Cut through electrical wiring at position -3-.
i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Headlights 145
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Electrical system - Edition 04.2019 en AG. Volkswagen AG
ag does
ksw not
y Vol gu
– Enclose one of the two wires leading d b to headlight reflector with ara
ise nte
heat-shrink hose -1-, heat it, thorand press together its end while eo
it is still warm using pliers.
ss au ra
c
ce
e
– Route both wire ends in headlight housing so that they are not
nl
pt
du
an
visible. itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Connect wiring of new bulb holder -1- to cut-through wires
leading to connector in headlight housing using butt connec‐
l purpos
tors -2-.
– Crimp butt connector -2-, and heat it with hot air blower until
nform
ercia
electrical wiring is completely sealed.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co
– Insert daytime running light bulb -L174- / -L175- -1- into bulb
by lksw
cted agen
Prote
holder -2-.
AG.
Caution
Risk of damage to the headlight.
♦ Do not touch the glass part of the bulb with bare fingers.
♦ Wear e.g. clean fabric gloves when inserting bulbs.
♦ Make sure the housing cover is correctly seated when in‐
stalling.
– Install bulb holder -2- into headlight.
– Route electrical wiring -1- properly in headlight housing, and
fix them using cable ties -2-.
146 Rep. gr.94 - Lights, bulbs, switches - exterior
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Electrical system - Edition 04.2019
– Install housing cover -1-.
– Install headlight ⇒ page 118 .
– Perform functional check.
– Check headlight setting and adjust headlight if necessary
⇒ Maintenance ; Booklet 20.1 ; Descriptions of work
1.13.4 Removing and installing daytime run‐
ning light bulb -L174- / -L175- , LED
headlights
Note
♦ The function of the daytime running light
wage
n AGbulb
. Volks-L174- / -L175-
wagen AG
doe
on LED headlights is performed Vol by the LED module for day‐ot gu
ks sn
by
time running lights. ris
ed ara
nt ee
tho
♦ The LED module forsdaytime running lights cannot be replaced or
au ac
individually. In the event
s of damage, the headlight must be re‐
ce
e
newed ⇒ page 118 .
nl
pt
du
an
itte
y li
erm
ab
1.14 Removing and installing output module
ility
ot p
for headlight -J667- / -J668- wit
, is n
h re
hole
spec
Special tools and workshop equipment required
es, in part or in w
t to the co
♦ Torque screwdriver - VAS 6494-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi
♦ Torque wrench 50-100Ncm - VAS 6253A-
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Headlights 147
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Electrical system - Edition 04.2019
♦ ESD workplace - VAS 6613-
Note
Removal and installation are described for the left side. The re‐
moval and installation procedure for the right-hand side is basi‐
cally the same.
Caution
Work on the output module may only be performed in an ESD
workplace.
n AG. Volkswagen AG do
lkswage es n
ot g
Removing d byV
o
ua
ran
ir se tee
– Remove headlight ⇒ page 118 . utho
or
a ac
ss
– Using a hammer, carefully detach housing cover on back of
ce
le
main beam LED module -1- around engineered break line
un
pt
an
d
-2-. Preferably, strike on the corners of the cover when doing
itte
y li
rm
this to prevent it from breaking.
ab
pe
ility
ot
– Remove housing cover -1- from headlight.
wit
, is n
h re
hole
Note spec
es, in part or in w
t to the co
The adjuster screws -top arrows- serve as a means of orientation.
rrectness of i
l purpos
– Separate electrical connector on headlight output module
-bottom arrow-.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
148 Rep. gr.94 - Lights, bulbs, switches - exterior
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Electrical system - Edition 04.2019
– Unscrew bolts -arrows-.
– Remove output module for headlight -1-.
AG. Volkswagen AG d
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Installing Volksw not
gu
by ara
ed
Install in the reverse order of removal, observinghothe
ris following: nte
eo
ut ra
s a c
s
Caution
ce
le
un
pt
an
d
itte
y li
Make sure cover seal is correctly seated when installing the
rm
ab
headlight power module . The ingress of water will cause per‐
pe
ility
ot
manent damage to the headlight.
wit
, is n
h re
hole
spec
– Check seal between headlight output module and headlight
es, in part or in w
t to the co
for damage.
Caution
rrectness of i
l purpos
Risk of damage to the headlight.
♦ Make sure the housing cover is correctly seated when in‐
nform
ercia
stalling. The ingress of water will cause permanent dam‐
age to the headlight.
m
a
com
tion in
r
te o
thi
s
iva
do
– Position new housing cover -1- onto headlight.
r
rp
cum
fo
– Screw in and tighten bolts -arrows-.
en
ng
t.
yi Co
op py
Specified torques t. C rig
gh ht
pyri by
♦ ⇒ “1.1.3 Assembly overview - LED headlights”, page 117
co Vo
by lksw
cted agen
Prote AG.
1.15 Removing and installing output module
1 for LED headlight -A27- / -A31-
Special tools and workshop equipment required
♦ Torque wrench 50-100Ncm - VAS 6253A-
1. Headlights 149
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Electrical system - Edition 04.2019
♦ ESD workplace - VAS 6613-
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
u
Note ss a ra
c
ce
e
nl
pt
du
Removal and installation are described for the left side. The re‐
an
itte
moval and installation procedure for the right-hand side is basi‐
y li
erm
ab
cally the same.
ility
ot p
wit
, is n
h re
hole
Caution
spec
es, in part or in w
t to the co
Work on the output module may only be performed in an ESD
workplace.
rrectness of i
Removing
l purpos
– Remove headlight ⇒ page 118 .
nform
ercia
– Unscrew three bolts -arrows- and remove LED headlight out‐
put module 1 -1-.
m
at
om
ion
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in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
150 Rep. gr.94 - Lights, bulbs, switches - exterior
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Electrical system - Edition 04.2019
Volkswagen AG
– Separate electrical connector -arrow- and remove LED head‐ swagen AG. does
light output module 1 -1-. by
Vol
k not
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ara
ed nte
Installing oris eo
th
au ra
c
Install in the reverse order of removal, observing thesfollowing:
s
ce
le
un
pt
an
d
itte
y li
Caution
erm
ab
ility
ot p
Ensure that the seal is correctly seated when installing the LED
wit
is n
headlight output module 1 . The ingress of water will cause
h re
ole,
permanent damage to the headlight.
spec
urposes, in part or in wh
t to the co
– Check seal between LED headlight output module 1 and head‐
light for damage.
rrectne
Specified torques
s
♦ ⇒ “1.1.3 Assembly overview - LED headlights”, page 117
s o
cial p
f inform
1.16 Removing and installing LED headlight
mer
atio
fan
om
n
c
i
or
n thi
Special tools and workshop equipment required
te
sd
iva
o
pr
♦ Torque screwdriver - VAS 6494-
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ ESD workplace - VAS 6613-
Note
Removal and installation are described for the left side. The re‐
moval and installation procedure for the right-hand side is basi‐
cally the same.
1. Headlights 151
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Electrical system - Edition 04.2019
Caution
Work on the LED headlight fan may only be performed in an
ESD workplace.
Removing
– Remove headlight ⇒ page 118 .
– Remove dipped beam LED module to gain access to electrical
connector ⇒ page 134 .
– Unscrew bolts -arrows-.
– Separate electrical connector -1- and remove fan -2-.
Installing
Install in the reverse order of removal, observing the following:
Caution
Risk of damage to the headlight.
♦ Make sure the housing cover is correctly seated when in‐
stalling. The ingress of water will cause permanent dam‐
age to the headlight.
– Before installing headlight, carry out fine adjustment of dipped
beam LED module ⇒ page 152 .
– Perform functional check.
n AG. Volkswagen AG do
wage es n
– Check headlight setting yand Vo adjust headlight if necessary
lks ot g
⇒ Maintenance ; Bookletir se
d b 20.1 ; Descriptions of work ua
ran
o tee
h
Specified torques s aut or
ac
s
♦ ⇒ “1.1.3 Assembly overview - LED headlights”, page 117
ce
le
un
pt
an
d
itte
y li
1.17 Fine adjustment of LED modules - LED
erm
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ility
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headlights
wit
is n
h re
ole,
spec
urposes, in part or in wh
Note
t to the co
♦ Following removal and installation or renewal of an LED mod‐
ule in the LED headlight, the main beam LED modules and
rrectne
dipped beam LED modules must be calibrated.
♦ The LED modules can be calibrated with the headlight re‐
ss
moved using the headlight extension cable ( test cable - VAS
o
cial p
f i
621 003- ) or with the headlight installed.
nform
mer
♦ When positioning the headlight in front of a wall, the distance
atio
m
must be 10 metres since the light pattern is far more distinct.
o
n
c
i
or
n thi
♦ The objective of the calibration is to align the light pattern of
te
sd
a
the main beam module with the light pattern of the dipped
iv
o
pr
beam module.
um
r
fo
en
ng
t.
yi Co
op
Preliminary work for calibration with headlight removed
C py
t. rig
gh ht
yri by
– Join electrical connector for headlight in vehicle and electrical cop Vo
by lksw
connector on headlight removed from vehicle to headlight ex‐
cted agen
Prote AG.
tension cable test cable - VAS 621 003- .
152 Rep. gr.94 - Lights, bulbs, switches - exterior
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Electrical system - Edition 04.2019
– Position removed headlights horizontallyaat genaAdistance
G. Volkswagof
enei‐
AG do
ther 5 or 10 metres in front of a wall.
V olksw es n
ot g
by ua
ed ran
Preliminary work for calibration hwith
or
is headlight installed tee
t or
au ac
– Position installed headlight
ss horizontally at a distance of either
5 or 10 metres in front of a wall.
ce
le
un
pt
an
d
itte
Continued for both calibration set-ups
y li
erm
ab
ility
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wit
is n
Note
h re
ole,
spec
♦ Adjust the main beam module in vertical direction by turning
urposes, in part or in wh
the two adjuster screws -1- and -2- on the back of the head‐
t to the co
light.
♦ Adjust the main beam module in horizontal direction by turning
rrectne
the outer adjuster screw (as seen in direction of travel) -1- on
the back of the headlight.
ss o
cial p
f
– Switch on main beam.
inform
mer
1. Vertical adjustment
atio
om
n
c
i
– Turn the »two adjuster screws« to set the bottom edge of the
or
n thi
e
light pattern of the main beam module -1- to the same height
t
sd
va
as the bottom edge of the light pattern of the dipped beam
i
o
pr
cum
r
module -2-.
fo
en
ng
t.
yi Co
2. Horizontal adjustment Cop py
t. rig
gh ht
pyri by
Vo
co lksw
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cted agen
Prote AG.
– Turn the »outer adjuster screw (as seen in direction of travel)«
until the two imaginary centre lines -3- of both light patterns
are on top of each other.
The bottom section of the illustration shows the light pattern for
properly calibrated LED modules.
– Install headlight as necessary ⇒ page 118 .
– Adjust headlights ⇒ page 120 .
1. Headlights 153
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Electrical system - Edition 04.2019
2 Fog lights
⇒ “2.1 Assembly overview - fog lights”, page 154
⇒ “2.2 Removing and installing fog light”, page 154
⇒ “2.3 Removing and installing fog light bulb L22 / L23 ”,
page 155
⇒ “2.4 Removing and installing static cornering light bulb”,
page 156
⇒ “2.5 Adjusting fog lights”, page 156
2.1 Assembly overview - fog lights
1 - Fog lights
❑ Removing and installing
⇒ page 154
2 - Bolt
❑ Qty. 2 agen
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❑ 2.2 Nm d byV gu
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3 - Bulb holder with fog light ut
ho eo
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bulb ss a c
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❑ Left fog light bulb - L22-
nl
pt
du
an
itte
❑ Right fog light bulb -
y li
erm
ab
L23-
ility
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❑ Removing and installing
wit
, is n
⇒ page 155
h re
hole
❑ Also fulfils function of
spec
es, in part or in w
static cornering light -
t to the co
L148- / -L149- depend‐
ing on equipment
4 - Front bumper cover
rrectness of i
❑ ⇒ General body repairs,
l purpos
exterior; Rep. gr. 63 ;
Front bumper; Assem‐
bly overview - bumper nform
ercia
cover
m
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ion
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in t
or
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ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2.2 Removing and installing fog light
Special tools and workshop equipment required
154 Rep. gr.94 - Lights, bulbs, switches - exterior
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Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1783-
AG. Volkswagen AG d
Removing agen oes
olksw not
y V gu
b ara
– Switch off ignition and all electrical
rise
d equipment and then re‐ nte
move ignition key. utho eo
ra
s a c
s
– Remove front bumper cover ⇒ General body repairs, exterior;
ce
e
nl
Rep. gr. 63 ; Removing and installing bumper cover .
pt
du
an
itte
y li
– Remove screws -1-.
erm
ab
ility
ot p
– Pull out fog light housing -2- sideways from mounting -3- in
wit
, is n
bumper cover.
h re
hole
spec
Installing
es, in part or in w
t to the co
Install in the reverse order of removal. When doing this, note the
following:
Specified torques
rrectness of i
♦ ⇒ “2.1 Assembly overview - fog lights”, page 154
l purpos
nf
ercia
orm
m
2.3 Removing and installing fog light bulb -
atio
om
n in
L22- / -L23-
or c
thi
te
sd
iva
Removing
o
r
rp
cu
o
m
f
– Switch off ignition and all electrical equipment and then re‐
en
ng
t.
yi
move ignition key.
Co
Cop py
t. rig
gh ht
– Open service flap -1- in front left wheel housing liner ⇒ Gen‐ yri
p by
o Vo
eral body repairs, exterior; Rep. gr. 66 ; Wheel housing liner;
c by lksw
cted agen
Assembly overview - front wheel housing liner .
Prote AG.
2. Fog lights 155
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Electrical system - Edition 04.2019
– Release and disconnect electrical connector -1-.
– Turn bulb holder -2- in direction of -arrow- and remove it from
fog light -3-.
Front fog light bulb -L22- / -L23- : H11 12V 55 W
Note
The left fog light bulb - L22- or right fog light bulb - L23- is per‐
manently fixed in the bulb holder and cannot be renewed individ‐
ually.
Installing
Install in the reverse order of removal. When doing this, note the
following:
Caution
Risk of damage to the headlight.
♦ Do not touch the glass part of the bulb with bare fingers.
Fingers leave traces of grease on the glass bulb, which
evaporate when the bulb is switched on and cause the
glass bulb to cloud over.
G. Volkswagen
♦ Wear clean fabric gloves when
lksw
agen inserting bulbs.
A AG do
es n
Vo ot g
by ua
♦ Make sure coverriscap
ed is correctly seated when installing.ran
The ingress ofuthwater will cause permanent damage to the ee or
o t
headlight. ss a ac
ce
e
nl
pt
du
an
itte
y li
– Check functioning of fog light.
erm
ab
ility
ot p
– Checking fog light settings and, if necessary, adjusting
wit
⇒ page 156 .
, is n
h re
hole
spec
2.4 Removing and installing static cornering
es, in part or in w
t to the co
light bulb
rrectness of i
Note
l purpos
♦ Depending on the vehicle equipment, the fog light bulbs -L22- /
-L23- are also used as the static cornering light bulbs -L148- /
nf
ercia
-L149- .
rm
m
atio
m
♦ Removing and installing fog light bulbs -L22- / -L23-
o
n in
c
⇒ page 155 .
or
thi
te
sd
iva
o
r
2.5 Adjusting fog lights
rp
cu
o
m
f
en
ng
t.
yi Co
Adjusting fog light ⇒ Maintenance ; Booklet 20.1 ; Work descrip‐ Cop py
tions . ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
156 Rep. gr.94 - Lights, bulbs, switches - exterior
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Electrical system - Edition 04.2019
3 Turn signal repeater
⇒ “3.1 Removing and installing turn signal repeater”, page 157
⇒ “3.2 Removing and installing turn signal repeater bulb M18/M19
”, page 158
3.1 Removing and installing turn signal re‐
peater
Special tools and workshop equipment required
♦ Removal wedge - 3409-
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
spec
♦ The illustrations show removal and installation of the left turn
es, in part or in w
signal light
t to the co
♦ Removal and installation of the right turn signal light are anal‐
ogous.
rrectness of i
Removing
l purpos
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
nform
mercia
at
om
Caution
on
c
in t
or
his
e
When removing and installing components that are in view
at
do
riv
(switches, covers, trims etc.), mask off areas in which tools
p
cum
or
(plastic wedge, screwdriver) are used to lever out those com‐
f
en
ng
t.
ponents using masking tape.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
– Carefully lever out front turn signal repeater -1- from installa‐
by lksw
cted agen
Prote
tion opening at position shown -arrow- using removal wedge.
AG.
3. Turn signal repeater 157
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Electrical system - Edition 04.2019
– Pull out primary locking element -1- -arrow A- and then press
-arrow B- to release.
– Pull off electrical connector -2- from bulb holder -3-.
Installing
Install in the reverse order of removal. When doing this, note the
following:
Caution
The metallic spring clip in the turn signal repeater can cause
damage to the paintwork in the installation opening during re‐
moval and installation.
Check the installation opening for paint damage and, if neces‐
sary, undertake corrosion protection measures (wax).
– Fit electrical connector and engage securely; push in primary
locking element.
– Insert turn signal repeater in installation opening at front first
with spring clip, and then push it in at rear and engage.
3.2 Removing and installing turn signal re‐
peater bulb - M18/M19-
AG. Volkswagen AG d
agen oes
olksw not
V gu
Note ed by ara
nte
ris
ho eo
ut ra
♦ The illustrations show removal and installation
ss a of the bulb for c
left turn signal - M18- .
ce
e
nl
pt
du
an
♦ Removal and installation of bulb for right turn signal - M19- are
itte
y li
analogous.
erm
ab
ility
ot p
wit
, is n
Removing
h re
hole
spec
– Switch off ignition and all electrical equipment and then re‐
es, in part or in w
move ignition key. t to the co
– Remove turn signal light ⇒ page 157 .
– Turn bulb holder -1- anti-clockwise to release -arrow- and pull
rrectness of i
out in straight line backwards out of turn signal repeater -2-.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
158 Rep. gr.94 - Lights, bulbs, switches - exterior
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Electrical system - Edition 04.2019
– Pull out turn signal repeater -1- in a straight line from bulb
holder -2-.
Turn signal repeater bulb - M18/M19- : glass-base bulb
12V, WY5W.
Installing
Install in the reverse order of removal. When doing this, note the
following:
– Following installation, check whether turn signal light is func‐
tioning correctly.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Turn signal repeater 159
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4 Lights in sill panel moulding
⇒ “4.1 Removing and installing entry light”, page 160
⇒ “4.2 Removing and installing bulb for entry light”, page 161
4.1 Removing and installing entry light
⇒ “4.1.1 Removing and installing entry light, Transporter”,
page 160
⇒ “4.1.2 Removing and installing entry light, Multivan”,
page 160
4.1.1 Removing and installing entry light,
Transporter
Removal and installation of all entry lights are performed in the
same manner and are described only for one light.
Caution
When removing and installing components that are in view
(switches, covers, trims etc.), mask off areas in which tools
(plastic wedge, screwdriver) are used to lever out those com‐
ponents using masking tape.
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Apply screwdriver (screwdriver handle must face towards in‐
side of vehicle) and carefully lever out light.
n AG. Volkswagen AG do
– Release and separate electrical connector. olkswage es n
ot g
byV ua
Installing ir se
d ran
tee
tho
or
Installation is carried out in the reverse sequence
ss
of
au
removal. ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
4.1.2 Removing and installing entry light, Mul‐
es, in part or in w
t to the co
tivan
Removal and installation of all entry lights are performed in the
rrectness of i
same manner and are described only for one light.
l purpos
Caution
nf
ercia
orm
When removing and installing components that are in view
m
atio
m
(switches, covers, trims etc.), mask off areas in which tools
o
n in
c
(plastic wedge, screwdriver) are used to lever out those com‐
or
thi
ponents using masking tape.
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
Removing
t.
yi Co
Cop py
. rig
– Switch off ignition and all electrical equipment and then re‐
t
gh ht
yri by
move ignition key. cop Vo
by lksw
cted agen
Prote AG.
160 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Fit screwdriver from left side and carefully lever out light.
– Release and separate electrical connector.
Installing
Install in the reverse order of removal. When doing this, note the
following:
Fit light first on left side and then engage spring.
4.2 Removing and installing bulb for entry
light
⇒ “4.2.1 Removing and installing bulb for entry light, Transporter”,
page 161
⇒ “4.2.2 Removing and installing bulb for entry light, Multivan”,
page 162
. Volkswagen AG
gen AG
4.2.1 Removing and installing olksbulb for entry
wa does
not
yV gu
light, Transporterorised
b ara
nte
th eo
au ra
Removing ss c
ce
le
un
– Switch off ignition and all electrical equipment and then re‐
pt
an
d
move ignition key.
itte
y li
erm
ab
– Remove entry light ⇒ page 160 .
ility
ot p
wit
is n
– Release locking lugs -1- and remove cover from bulb carrier
h re
ole,
-2-.
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
– Carefully lever defective bulb out of bulb holder.
te
sd
iva
o
r
– Entry light bulb : glass-base bulb 12V, 5 W
p
cum
r
fo
en
ng
t.
Installing
yi Co
Cop py
ht. rig
Installation is carried out in the reverse sequence of removal. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Lights in sill panel moulding 161
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Electrical system - Edition 04.2019
4.2.2 Removing and installing bulb for entry
light, Multivan
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove entry light ⇒ page 160 .
– Release locking lugs -1-, and detach bulb carrier -2- from
housing of light.
– Carefully pull defective bulb out of bulb holder.
– Entry light bulb : glass-base bulb 12V, 1.2 W
Note
To check which bulb is defective, the connector can be fitted to
the lamp carrier.
AG. Volkswagen AG d
agen oes
Installing Volksw not
gu
by ara
d
Installation is carried out in the reverse sequence of removal.
orise nte
eo
th
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
162 Rep. gr.94 - Lights, bulbs, switches - exterior
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Electrical system - Edition 04.2019
5 Tail lights
⇒ “5.1 Assembly overview - tail lights”, page 163
⇒ “5.2 Removing and installing bulb carrier”, page 167
⇒ “5.3 Removing and installing tail light cluster”, page 169
⇒ “5.4 Removing and installing tail light bulb M2 / M4 ”,
page 171
⇒ “5.5 Removing and installing rear fog light bulb L46 / L47 ”, page
174
⇒ “5.6 Removing and installing brake light bulb M9 / M10 ”, page
177
⇒ “5.7 Removing and installing reversing light bulb M16 / M17 ”,
page 180
⇒ “5.8 Removing and installing turn signal bulb M6 / M8 ”,
page 184
5.1 Assembly overview - tail lights
⇒ “5.1.1 Assembly overview - tail lights, rear wing doors”,
page 163
⇒ “5.1.2 Assembly overview - tail lights, rear lid”, page 165
⇒ “5.1.3 Assembly overview - tail lights, rear lid (LED)”,
page 166
⇒ “5.1.4 Assembly overview - tail lights, dropside vehicles”, page
167
5.1.1 Assembly
swa
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5. Tail lights 163
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➤ , Multivan 2016 ➤ , Transporter 20 ...e or a
Electrical system - Edition 04.2019
ss c
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nl
pt
du
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1 - Ball heads to body
itte
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❑ Qty. 2
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❑ For securing tail light
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cluster
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es, in part or in w
t to the co
2 - Electrical connector
3 - Brake light bulb -M9- / -
M10-
rrectness of i
❑ 12 V, W16W
l purpos
❑ Removing and installing
⇒ page 177
nf
ercia
o
4 - Turn signal bulb -M6- / -M8-
rm
m
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❑ 12V, WY16W
om
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c
❑ Removing and installing
or
thi
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⇒ page 184
t
sd
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5 - Tail light
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❑ Removing and installing
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⇒ page 169
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❑ Qty. 2
❑ 4 Nm
7 - Reversing light bulb -M16- /
-M17-
❑ 12V, W16W
❑ Removing and installing
⇒ page 180
8 - Rear fog light bulb -L46- / -
L47-
❑ Driver side only
❑ 12V, P 21/4W
❑ Removing and installing ⇒ page 174
9 - Bulb carrier
❑ Removing and installing ⇒ page 167
❑ 4 bolts securing bulb carrier to tail light housing
❑ 1 Nm
10 - Tail light bulb -M4-
❑ 12 V W5W
❑ Removing and installing ⇒ page 171
11 - Tail light bulb -M4-
❑ 12 V W5W
❑ Removing and installing ⇒ page 171
12 - Ball head mountings to tail light cluster
❑ Qty. 2
164 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
5.1.2 Assembly overview - tail lights, rear lid
1 - Ball heads to body
❑ Qty. 2
❑ For securing tail light
cluster
❑ 1.5 Nm
2 - Electrical connector AG. Volkswagen AG d
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3 - Brake and tail light bulb - by Vo gu
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❑ 12 V, P21/5W s aut ra
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❑ Removing and installing
ce
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un
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⇒ page 178
an
d
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4 - Turn signal bulb -M6- / -M8-
rm
ab
pe
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❑ 12V, WY16W
ot
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❑ Removing and installing
h re
hole
⇒ page 185
spec
es, in part or in w
5 - Tail light
t to the co
❑ Removing and installing
⇒ page 169
rrectness of i
6 - Bolts securing tail light clus‐
l purpos
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❑ Qty. 2
nform
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❑ 4 Nm
m
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7 - Reversing light bulb -M16- /
com
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⇒ page 181
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8 - Rear fog light bulb -L46- / - C py
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❑ Driver side only
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❑ 12V, H21W
❑ Removing and installing ⇒ page 175
9 - Bulb carrier
❑ Removing and installing ⇒ page 168
❑ 4 bolts securing bulb carrier to tail light housing
❑ 1 Nm
10 - Tail light bulb -M4-
❑ 12 V W5W
❑ Removing and installing ⇒ page 172
11 - Ball head mountings to tail light cluster
❑ Qty. 2
5. Tail lights 165
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Electrical system - Edition 04.2019
5.1.3 Assembly overview - tail lights, rear lid (LED)
1 - Ball heads to body
❑ Qty. 2
❑ 1.5 Nm
2 - Electrical connector
3 - Reversing light bulb -M16- /
-M17-
❑ 12V, W16W
❑ Removing and installing
⇒ page 182
4 - Tail light
❑ Following functions are
performed by light-emit‐
ting diodes. Lighting el‐
ements cannot be re‐
placed individually.
AG. Volkswagen AG d
❑ Tail light bulb -M4- / - lksw
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not
M4- ⇒ page 173 d by Vo gu
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❑ Rear fog light bulb -tho ri
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L46- / -L47- s au ra
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⇒ page 176 s
ce
e
nl
❑ Brake light bulb -M9- / - pt
du
an
itte
M10- ⇒ page 179 y li
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❑ Removing and installing ility
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tail light ⇒ page 169
wit
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5 - Bolts securing tail light clus‐
hole
spec
ter
es, in part or in w
t to the co
❑ Qty. 2
❑ 4 Nm
rrectness of i
6 - Turn signal bulb -M6- / -M8-
❑ 12V, WY16W
l purpos
❑ Removing and installing
⇒ page 186
nf
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7 - Ball head mountings to tail light cluster
m
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❑ Qty. 2
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166 Rep. gr.94 - Lights, bulbs, switches - exterior
AG. Volkswagen AG d
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horis California 2016 ➤ , Caravelle 2016 ➤e o, Multivan 2016 ➤ , Transporter 20 ...
ut
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a ra
ss
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un
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5.1.4 Assembly overview - tail lights, dropside vehicles
an
d
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1 - Securing bolts for lens
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❑ Securing bolts for lens:
ole,
spec
0.75 Nm
urposes, in part or in wh
❑ Securing nuts of cap:
t to the co
6 Nm
❑ Securing nuts of tail
rrectne
light: 6 Nm
2 - Lens
ss o
3 - Bulb carrier
cial p
f inform
❑ Removing and installing
mer
⇒ page 169
atio
om
n
c
4 - Rear left turn signal bulb -
i
or
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M6- or rear right turn signal
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bulb - M8-
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❑ 12V, P 21 W
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❑ Removing and installing Cop py
⇒ page 187
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5 - Left brake light bulb - M9-
by c lksw
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or right brake light bulb - M10-
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❑ 12V, P 21W
❑ Removing and installing
⇒ page 179
6 - Left tail light bulb - M4- or right tail light bulb - M2-
❑ Qty. 2 12V, P 5 W each
❑ Removing and installing ⇒ page 173
7 - Left reversing light bulb - M16- or right reversing light bulb - M17-
❑ 12V, P 21 W
❑ Removing and installing ⇒ page 183
8 - Left rear fog light bulb - L46-
❑ Only driver side, 12V, P 21W
❑ Removing and installing ⇒ page 176
5.2 Removing and installing bulb carrier
⇒ “5.2.1 Removing and installing bulb carrier, rear wing doors”,
page 167
⇒ “5.2.2 Removing and installing bulb carrier, rear lid”,
page 168
⇒ “5.2.3 Removing and installing bulb carrier, rear lid (LED)”, page
169
⇒ “5.2.4 Removing and installing bulb carrier, dropside vehicle”,
page 169
5.2.1 Removing and installing bulb carrier,
rear wing doors
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove tail light ⇒ page 169 .
5. Tail lights 167
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Electrical system - Edition 04.2019
– Unscrew the four securing bolts -arrows-.
– Remove bulb carrier -1- from tail light -2-.
Installing
Install in the reverse order of removal. When doing this, note the
following:
– Check that seal around bulb carrier is seated correctly and not
damaged.
– Insert bulb carrier -1- in tail light cluster -2- and tighten securing
bolts -arrows-.
Specified torques AG. Volkswagen AG d
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♦ ⇒ “5.1.1 Assembly overview - tail lights, rear wing doors”,isepage
d b ara
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163 . hor eo
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5.2.2 Removing and installing bulb carrier,
es, in part or in w
t to the co
rear lid
Removing
rrectness of i
– Switch off ignition and all electrical equipment and then re‐
l purpos
move ignition key.
– Remove tail light ⇒ page 169 .
nform
ercia
– Unscrew the four securing bolts -arrows-.
m
at
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– Remove bulb carrier -1- from tail light -2-.
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– Insert bulb carrier -1- in tail light cluster -2- and tighten securing
bolts -arrows-.
Specified torques
♦ ⇒ “5.1.2 Assembly overview - tail lights, rear lid”, page 165
168 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
5.2.3 Removing and installing bulb carrier,
rear lid (LED)
Note
♦ LED tail lights do not have any replaceable lighting elements.
♦ The tail light bulbs are light-emitting diodes and are integrated
in the tail lights. These light-emitting
agen
diodes
AG. Volkswcannot
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newed in the course of repair. ol The
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♦ The turn signal bulb
au and reversing light bulb can be replaced
th or
ac
directly in the tail
ss light housing.
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5.2.4 Removing and installing bulb carrier,
itte
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dropside vehicle
ility
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spec
Note
urposes, in part or in wh
t to the co
The procedure for removal and installation of the bulb carrier on
vehicles with a dropside body is as per removal and installation
of the tail light cluster ⇒ page 170 .
rrectne
5.3 Removing and installing tail light cluster
ss o
cial p
f in
⇒ “5.3.1 Removing and installing tail light, rear wings doors and
form
rear lid”, page 169
mer
atio
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⇒ “5.3.2 Removing and installing tail light, dropside vehicles”,
o
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page 170
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5.3.1 Removing and installing tail light, rear
i
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wings doors and rear lid
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Special tools and workshop equipment required Prote AG.
♦ Torque wrench - V.A.G 1783-
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– On vehicles with rear wing doors, fully open the door in ques‐
tion so that the tail light does not strike against the apex of the
door aperture.
5. Tail lights 169
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Electrical system - Edition 04.2019
– Unscrew two securing bolts -arrows- and remove tail light
cluster outwards from ball studs.
– Release and disconnect connector -arrow-.
Installing
Install in the reverse order of removal. When doing this, note the
following: agen
AG. Volkswagen AG d
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– Connect connector and dengage
by
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– Insert tail light cluster in body aperture and insert mountings h re
hole
-1- from the side onto the ball heads -2-. spec
es, in part or in w
– Swing tail light cluster towards body, align and tighten with
t to the co
securing bolts.
Specified torques
rrectness of i
♦ ⇒ “5.1.1 Assembly overview - tail lights, rear wing doors”, page
l purpos
163
nform
mercia
at
om
ion
c
in t
or
his
5.3.2 Removing and installing tail light, drop‐
ate
do
riv
side vehicles
p
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t.
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The removal and installation procedure is carried out in the same
Co
Cop py
way on both sides and is described for just one light. ht. rig
rig ht
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Special tools and workshop equipment required by c lksw
cted agen
Prote AG.
♦ Torque wrench - V.A.G 1783-
170 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Unscrew securing bolts -1- of lens -2-.
– Remove bulb carrier -3-.
– Pull off connectors.
– Unscrew securing nuts -1- Aand
G. Voremove
lkswagencover
A
cap -2-.
gen G do
swa es
– Unscrew securing
by
Vonuts
lk -3- and remove tail lightnocluster
t gu -4-.
ara
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Installing ris
tho e or
au ac
Install in the
ss reverse order of removal. When doing this, note the
ce
le
following:
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– On assembly, rubber seal of scatter lens must be installed in‐
es, in part or in w
t to the co
wards in lower corners of light -arrows- to act as water drain
aperture.
Specified torques
rrectness of i
♦ ⇒ “5.1.4 Assembly overview - tail lights, dropside vehicles”,
l purpos
page 167 .
nform
mercia
a
com
tion in
r
te o
thi
s
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5.4 Removing and installing tail light bulb -
en
ng
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M2- / -M4-
Cop py
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⇒ “5.4.1 Removing and installing tail light bulb M2 / M4 , rear wing
cop Vo
by lksw
doors”, page 171
cted agen
Prote AG.
⇒ “5.4.2 Removing and installing tail light bulb M2 / M4 , rear lid”,
page 172
⇒ “5.4.3 Removing and installing tail light bulb M2 / M4 , LED tail
lights”, page 173
⇒ “5.4.4 Removing and installing tail light bulb M2 / M4 , dropside”,
page 173
5.4.1 Removing and installing tail light bulb -
M2- / -M4- , rear wing doors
Special tools and workshop equipment required
5. Tail lights 171
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Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1783-
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove bulb holder ⇒ page 167 .
– Pull tail light bulb -5- and -6- in straight line out of bulb carrier
-7-.
Tail light bulb -M2- / -M4- : glass-base bulb 12V, W5W
Note
♦ The rear fog light bulb -L46- / -L47- -4- also fulfils a tail light
function.
. Volkswagen AG
♦ Removing and installing rear fog light bulb -L46- / -L47- kswagen AG does
⇒ page 174 . Vol y
not
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Installing s au ra
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s
Install in the reverse order of removal. When doing this, note the
ce
le
un
pt
following:
an
d
itte
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rm
ab
pe
Caution ility
ot
wit
, is n
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Risk of damage to the bulb.
hole
spec
es, in part or in w
♦ Do not touch the glass part of the bulb with bare fingers.
t to the co
Fingers leave traces of grease on the glass bulb, which
evaporate when the bulb is switched on and cause the
glass bulb to cloud over.
rrectness of i
♦ Wear clean fabric gloves when inserting bulbs.
l purpos
nform
ercia
Specified torques
m
♦ ⇒ “5.1.1 Assembly overview - tail lights, rear wing doors”, page
a
com
tio
163 .
n in
r
te o
thi
s
iva
5.4.2 Removing and installing tail light bulb -
do
r
rp
cum
M2- / -M4- , rear lid
fo
en
ng
t.
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op py
Special tools and workshop equipment required t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
172 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1783-
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove bulb holder ⇒ page 168 .
olkswagen AG
en AG. V
– Pull out tail light bulbsol-4-
ksw in a straight line from bulb
ag does
not carrier
-5-. ed by V gu
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Tail light bulb -M2-
au
th / -M4- : glass-base bulb 12V, W5W eo
ra
ss c
Installing
ce
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un
pt
an
d
Install in the reverse order of removal. When doing this, note the
itte
following: y li
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ab
ility
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wit
is n
Caution
h re
ole,
spec
urposes, in part or in wh
Risk of damage to the bulb.
t to the co
♦ Do not touch the glass part of the bulb with bare fingers.
Fingers leave traces of grease on the glass bulb, which
evaporate when the bulb is switched on and cause the
rrectne
glass bulb to cloud over.
s
♦ Wear clean fabric gloves when inserting bulbs.
s o
cial p
f inform
mer
Specified torques
atio
om
♦ ⇒ “5.1.2 Assembly overview - tail lights, rear lid”, page 165 .
c
i
or
n thi
te
sd
va
5.4.3 Removing and installing tail light bulb -
i
o
pr
cum
r
fo
M2- / -M4- , LED tail lights
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
Note
co lksw
by
cted agen
Prote AG.
♦ The tail light bulb uses light-emitting diodes and is integrated
in the tail lights.
♦ Exchange of the light-emitting diodes in the course of repair is
not possible. The tail light must be renewed completely
⇒ page 169 .
5.4.4 Removing and installing tail light bulb -
M2- / -M4- , dropside
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
5. Tail lights 173
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Electrical system - Edition 04.2019
– Unscrew securing bolts -1- of lens -2-.
– Push tail light bulb -6- into holder, turn anti-clockwise and pull
out of bulb carrier -3-.
Left tail light bulb - M4- or right tail light bulb - M2- , qty. 2 each,
12 V, P 5 W
AG. Volkswagen AG d
Installing lksw
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not
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Install in the reverse order of removal. When doing risedthis, note the
b ara
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following: ut
ho eo
ra
s a c
s
ce
le
Caution
un
pt
an
d
itte
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erm
ab
Risk of damage to the bulb.
ility
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♦ Do not touch the glass part of the bulb with bare fingers.
wit
is n
h re
Fingers leave traces of grease on the glass bulb, which
ole,
evaporate when the bulb is switched on and cause the
spec
urposes, in part or in wh
glass bulb to cloud over.
t to the co
♦ Wear clean fabric gloves when inserting bulbs.
rrectne
– On assembly, rubber seal of scatter lens must be installed in‐
s
wards in lower corners of light -arrows- to act as water drain
s o
cial p
f
aperture.
inform
mer
Specified torques
atio
m
♦ ⇒ “5.1.4 Assembly overview - tail lights, dropside vehicles”,
o
n
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i
or
n
page 167
thi
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5.5 Removing and installing rear fog light
bulb -L46- / -L47-
⇒ “5.5.1 Removing and installing rear fog light bulb L46 / L47 ,
rear wing doors”, page 174
⇒ “5.5.2 Removing and installing rear fog light bulb L46 / L47 ,
rear lid”, page 175
⇒ “5.5.3 Removing and installing rear fog light bulb L46 / L47 ,
rear lid (LED)”, page 176
⇒ “5.5.4 Removing and installing rear fog light bulb L46 / L47 ,
dropside”, page 176
5.5.1 Removing and installing rear fog light
bulb -L46- / -L47- , rear wing doors
Special tools and workshop equipment required
174 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1783- AG. Volkswagen AG d
agen oes
olksw not
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un
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itte
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ab
ility
ot p
wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
Removing
rrectne
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
s
– Remove bulb holder ⇒ page 167 .
s o
cial p
f in
– Push rear fog light bulb -L46- / -L47- -4- into holder, turn anti-
form
mer
clockwise and pull out of bulb carrier -7-.
atio
m
Rear fog light bulb -L46- / -L47- : 12V, P 21/4W
o
n
c
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♦ The rear fog light bulb -L46- / -L47- -4- also fulfils a tail light Cop py
function.
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Vo
co
♦ Removing and installing tail light bulbs -M2- / -M4-
by lksw
cted agen
Prote
⇒ page 171 .
AG.
Installing
Install in the reverse order of removal. When doing this, note the
following:
Caution
Risk of damage to the bulb.
♦ Do not touch the glass part of the bulb with bare fingers.
Fingers leave traces of grease on the glass bulb, which
evaporate when the bulb is switched on and cause the
glass bulb to cloud over.
♦ Wear clean fabric gloves when inserting bulbs.
Specified torques
♦ ⇒ “5.1.1 Assembly overview - tail lights, rear wing doors”, page
163
5.5.2 Removing and installing rear fog light
bulb -L46- / -L47- , rear lid
Special tools and workshop equipment required
5. Tail lights 175
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Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1783-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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o
Removing auth eo
ra
ss c
– Switch off ignition and all electrical equipment and then re‐
ce
e
nl
pt
move ignition key.
du
an
itte
y li
– Remove left bulb holder ⇒ page 168 .
erm
ab
ility
ot p
– Push rear fog light bulb -3- into holder, turn anti-clockwise and
wit
, is n
pull out of bulb carrier -5-.
h re
hole
spec
Rear fog light bulb -L46- / -L47- : 12V, H21W
es, in part or in w
t to the co
Installing
Install in the reverse order of removal. When doing this, note the
rrectness of i
following:
l purpos
Caution
nf
ercia
Risk of damage to the bulb.
orm
m
atio
♦ Do not touch the glass part of the bulb with bare fingers.
om
n in
Fingers leave traces of grease on the glass bulb, which
or c
thi
evaporate when the bulb is switched on and cause the
te
sd
a
glass bulb to cloud over.
iv
o
r
rp
cu
o
m
♦ Wear clean fabric gloves when inserting bulbs.
f
en
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t.
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Cop py
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gh ht
yri by
Specified torques cop Vo
by lksw
cted agen
Prote
♦ ⇒ “5.1.2 Assembly overview - tail lights, rear lid”, page 165
AG.
5.5.3 Removing and installing rear fog light
bulb -L46- / -L47- , rear lid (LED)
Note
♦ The rear fog light bulb uses light-emitting diodes and is inte‐
grated in the tail lights.
♦ Exchange of the light-emitting diodes in the course of repair is
not possible. The tail light must be renewed completely
⇒ page 169 .
5.5.4 Removing and installing rear fog light
bulb -L46- / -L47- , dropside
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
176 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Unscrew securing bolts -1- of lens -2-.
– Push rear fog light bulb -8- into holder, turn anti-clockwise and
pull out of bulb carrier -3-.
Rear left fog light bulb - L46- : only driver side 12 V, P 21 W
Installing
Install in the reverse order of removal. When doing this, note the
following: n AG. Volkswagen A age G do
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y Vol ot g
ua
b
Caution ris
ed ran
tee
tho
or
au ac
Risk of damage to the bulb.ss
ce
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un
pt
♦ Do not touch the glass part of the bulb with bare fingers.
an
d
itte
Fingers leave traces of grease on the glass bulb, which
y li
erm
ab
evaporate when the bulb is switched on and cause the
ility
ot p
glass bulb to cloud over.
wit
is n
h re
♦ Wear clean fabric gloves when inserting bulbs.
ole,
spec
urposes, in part or in wh
t to the co
– On assembly, rubber seal of scatter lens must be installed in‐
wards in lower corners of light -arrows- to act as water drain
rrectne
aperture.
Specified torques
ss o
♦ ⇒ “5.1.4 Assembly overview - tail lights, dropside vehicles”,
cial p
f in
page 167
form
mer
atio
om
n
c
i
or
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5.6 Removing and installing brake light bulb
t. C rig
gh ht
yri by
-M9- / -M10-
cop Vo
by lksw
cted agen
Prote AG.
⇒ “5.6.1 Removing and installing brake light bulb M9 / M10 , rear
wing doors”, page 177
⇒ “5.6.2 Removing and installing brake and tail light bulb M21 /
M22 , rear lid”, page 178
⇒ “5.6.3 Removing and installing brake light bulb M9 / M10 , rear
lid (LED)”, page 179
⇒ “5.6.4 Removing and installing brake light bulb M9 / M10 , drop‐
side”, page 179
5.6.1 Removing and installing brake light bulb
-M9- / -M10- , rear wing doors
Special tools and workshop equipment required
5. Tail lights 177
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Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1783-
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove bulb holder ⇒ page 167 .
– Pull out brake light bulb -M9- / -M10- -1- in a straight line from
bulb carrier -7-.
Brake light bulb -M9- / -M10- : 12V, W16W
Installing
Install in the reverse order of removal. When doing this, note the
following:
Caution
AG. Volkswagen AG d
Risk of damage to the bulb. agen oes
olksw not
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by ara
♦ Do not touch the glass opart
ris of the bulb with bare fingers.
ed
nte
Fingers leave tracesauof
t grease on the glass bulb, which
h eo
ra
evaporate when thes bulb is switched on and cause the
s c
glass bulb to cloud over.
ce
le
un
pt
an
d
itte
♦ Wear clean fabric gloves when inserting bulbs.
y li
rm
ab
pe
ility
ot
wit
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Specified torques
h re
hole
spec
♦ ⇒ “5.1.1 Assembly overview - tail lights, rear wing doors”, page
es, in part or in w
163
t to the co
5.6.2 Removing and installing brake and tail
rrectness of i
light bulb -M21- / -M22- , rear lid
l purpos
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
178 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove bulb holder ⇒ page 168 .
– Push brake and tail light bulbs -2- into holder, turn anti-clock‐
wise and pull out of bulb carrier -5-.
Brake and tail light bulb -M21- / -M22- :e12V,
n AG. VP21/5W
olkswagen AG
wag does
Installing olks not
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ara
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ris
Install in the reverse ordertho of removal. When doing this, note the eo
following: au ra
c
ss
ce
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un
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an
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Caution
itte
y li
erm
ab
ility
Risk of damage to the bulb.
ot p
wit
is n
♦ Do not touch the glass part of the bulb with bare fingers.
h re
ole,
Fingers leave traces of grease on the glass bulb, which
spec
urposes, in part or in wh
evaporate when the bulb is switched on and cause the
t to the co
glass bulb to cloud over.
♦ Wear clean fabric gloves when inserting bulbs.
rrectne
Specified torques
ss o
cial p
♦ ⇒ “5.1.2 Assembly overview - tail lights, rear lid”, page 165 .
f inform
mer
5.6.3 Removing and installing brake light bulb
atio
om
n
c
-M9- / -M10- , rear lid (LED) i
or
n thi
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Note
en
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Cop py
♦ The brake light bulb uses light-emitting diodes and is integra‐
t. rig
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ted in the tail lights.
p by
co Vo
by lksw
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♦ Exchange of the light-emitting diodes in the course of repair is
Prote AG.
not possible. The tail light must be renewed completely
⇒ page 169 .
5.6.4 Removing and installing brake light bulb
-M9- / -M10- , dropside
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
5. Tail lights 179
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Electrical system - Edition 04.2019
– Unscrew securing bolts -1- of lens -2-.
– Push brake light bulb -5- into holder, turn anti-clockwise and
pull out of bulb carrier -3-.
Left brake light bulb - M9- or right brake light bulb - M10- , 12V,
P 21W
Installing
Install in the reverse order of removal. When doing this, note the
following:
Caution
Risk of damage to the bulb.
♦ Do not touch the glass part of the bulb with bare fingers.
Fingers leave traces of grease on the glass bulb, which
evaporate when the bulb is switched on and cause the
glass bulb to cloud over. en AG. V
olkswagen AG
ag does
lksw not
♦ Wear clean fabric gloves when inserting bulbs.
db
yV
o gu
ara
e nte
ris
tho eo
au ra
c
ss
– On assembly, rubber seal of scatter lens must be installed in‐
ce
e
nl
pt
du
wards in lower corners of light -arrows- to act as water drain
an
itte
y li
aperture.
erm
ab
ility
ot p
Specified torques
wit
, is n
h re
♦ ⇒ “5.1.4 Assembly overview - tail lights, dropside vehicles”,
hole
page 167 .
spec
es, in part or in w
t to the co
rrectness of i
l purpos
5.7 Removing and installing reversing light nf
ercia
bulb -M16- / -M17-
rm
m
atio
om
⇒ “5.7.1 Removing and installing reversing light bulb M16 / M17 ,
n in
or c
rear wing doors”, page 180
thi
te
sd
iva
⇒ “5.7.2 Removing and installing reversing light bulb M16 / M17 ,
o
r
rp
cu
rear lid”, page 181
o
m
f
en
ng
t.
yi Co
⇒ “5.7.3 Removing and installing reversing light bulb M16 / M17 , Cop py
t. rig
rear lid (LED)”, page 182 opyri
gh by
Vo
ht
by c lksw
⇒ “5.7.4 Removing and installing reversing light bulb M16 / M17 , Prote
cted agen
dropside”, page 183
AG.
5.7.1 Removing and installing reversing light
bulb -M16- / -M17- , rear wing doors
Special tools and workshop equipment required
180 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1783-
Removing
– Switch off ignition and all electrical equipment gand
en AGthen
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wagen AG
does
swa
move ignition key. yV
olk not
gu b ara
ed
– Remove bulb holder ⇒ page 167tho.ris nte
e or
au ac
– Pull out reversing light bulb -M16-
ss / -M17- -3- in a straight line
ce
e
from bulb carrier -7-.
nl
pt
du
an
itte
Reversing light bulb -M16- / -M17- : 12V, W16W
y li
erm
ab
ility
Installing
ot p
wit
, is n
Install in the reverse order of removal. When doing this, note the
h re
hole
following:
spec
es, in part or in w
t to the co
Caution
Risk of damage to the bulb.
rrectness of i
♦ Do not touch the glass part of the bulb with bare fingers.
l purpos
Fingers leave traces of grease on the glass bulb, which
evaporate when the bulb is switched on and cause the
nform
ercia
glass bulb to cloud over.
m
at
♦ Wear clean fabric gloves when inserting bulbs.
om
ion
c
in t
or
his
ate
Specified torques
do
priv
cum
or
♦ ⇒ “5.1.1 Assembly overview - tail lights, rear wing doors”, page
f
en
ng
t.
yi
163 .
Co
Cop py
ht. rig
rig ht
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5.7.2 Removing and installing reversing light
co Vo
by lksw
cted agen
bulb -M16- / -M17- , rear lid
Prote AG.
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-
5. Tail lights 181
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Electrical system - Edition 04.2019
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove right-hand bulb carrier ⇒ page 168 .
– Push reversing light bulbs -3- into holder, turn anti-clockwise
and pull out of bulb carrier -5-. n AG. Volkswagen A G do
wage es n
Reversing light bulb -M16- / -M17- : 12V, P21W olks ot g
byV ua
ed ran
Installing ris tee
tho or
au ac
Install in the reverse order of removal. Whenssdoing this, note the
ce
e
following:
nl
pt
du
an
itte
y li
erm
ab
Caution
ility
ot p
wit
, is n
Risk of damage to the bulb.
h re
hole
spec
♦ Do not touch the glass part of the bulb with bare fingers.
es, in part or in w
Fingers leave traces of grease on the glass bulb, which
t to the co
evaporate when the bulb is switched on and cause the
glass bulb to cloud over.
rrectness of i
♦ Wear clean fabric gloves when inserting bulbs.
l purpos
Specified torques
nf
ercia
o
♦ ⇒ “5.1.2 Assembly overview - tail lights, rear lid”, page 165 .
rm
m
atio
om
n in
c
5.7.3 Removing and installing reversing light
or
thi
te
bulb -M16- / -M17- , rear lid (LED)
sd
iva
o
r
rp
cu
o
m
f
Special tools and workshop equipment required
en
ng
t.
yi Co
op
♦ Torque wrench - V.A.G 1783-
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove tail light ⇒ page 169 .
182 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Turn bulb holder anti-clockwise in direction of -arrow- and pull
out reversing light bulb -1- from tail light housing -3-.
– Pull out reversing light bulb -2- in a straight line from bulb
holder -1-.
Reversing light bulb -M16- / -M17- : 12V, W16 W
Installing
Install in the reverse order of removal. When doing this, note the
following:
Caution
Risk of damage to the bulb.
♦ Do not touch the glass part of the bulb with bare fingers.
Fingers leave traces of grease on the glass bulb, which
evaporate when the bulb is switched on and cause the
glass bulb to cloud over.
♦ Wear clean fabric gloves when inserting bulbs.
n AG. Volkswagen AG
wage does
Volks not
gu
by ara
ed
Specified torques thoris nte
eo
au ra
♦ ⇒ “5.1.3 Assembly
ss overview - tail lights, rear lid (LED)”, c
ce
page 166 .
le
un
pt
an
d
itte
y li
erm
5.7.4 Removing and installing reversing light
ab
ility
ot p
bulb -M16- / -M17- , dropside
wit
is n
h re
ole,
Removing
spec
urposes, in part or in wh
– Switch off ignition and all electrical equipment and then re‐
t to the co
move ignition key.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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Cop py
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rig ht
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co Vo
by lksw
cted agen
Prote AG.
5. Tail lights 183
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Electrical system - Edition 04.2019
– Unscrew securing bolts -1- of lens -2-.
– Push reversing light bulb -7- into holder, turn anti-clockwise
and pull out of bulb carrier -3-.
Left reversing light bulb - M16- or right reversing light bulb - M17-
12V, P 21 W
Installing
Install in the reverse order of removal. When doing this, note the
following:
Caution
Risk of damage to the bulb.
♦ Do not touch the glass part of the bulb with bare fingers.
Fingers leave traces of grease on the glass bulb, which
evaporate when the bulb is switched on and cause the
glass bulb to cloud over.
♦ Wear clean fabric gloves when inserting bulbs.
n AG. Volkswagen AG do
lk swage es n
o ot g
byV ua
– On assembly, rubber seal of scatter ir selens must be installed in‐
d ran
tee
wards in lower corners of light -arrows-
autho
to act as water drain or
ac
aperture. ss
ce
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un
Specified torques
pt
an
d
itte
y li
♦ ⇒ “5.1.4 Assembly overview - tail lights, dropside vehicles”,
erm
ab
page 167 .
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
5.8 Removing and installing turn signal bulb
-M6- / -M8-
ss o
cial p
f i
⇒ “5.8.1 Removing and installing turn signal bulb M6 / M8 , rear
nform
wing doors”, page 184
mer
atio
m
⇒ “5.8.2 Removing and installing turn signal bulb M6 / M8 , rear
o
n
c
lid”, page 185
or
n thi
te
sd
va
⇒ “5.8.3 Removing and installing turn signal bulb M6 / M8 , rear
i
o
pr
cum
lid (LED)”, page 186
r
fo
en
ng
t.
yi
⇒ “5.8.4 Removing and installing turn signal bulb M6 / M8 , drop‐
Co
Cop py
side”, page 187
t. rig
gh ht
pyri by
Vo
o
5.8.1 Removing and installing turn signal bulb
c by lksw
cted agen
Prote AG.
-M6- / -M8- , rear wing doors
Special tools and workshop equipment required
184 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1783-
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove bulb holder ⇒ page 167 .
– Pull out turn signal bulb -M6- / -M8- -2- in a straight line from
bulb carrier -7-.
Turn signal bulb -M6- / -M8- : 12V, W16W
Installing
Install in the reverse order of removal. When doing this, note the
following:
Caution
Risk of damage to the bulb.
♦ Do not touch the glass part of the bulb with bare fingers.
Fingers leave traces of grease on the glass bulb, which
evaporate when the bulb is switched on and cause the
glass bulb to cloud over. swa
gen AG
. Volkswagen AG
does
k not
Vol
♦ Wear clean fabric gloves when inserting bulbs.
y gu
db ara
se ri nte
ho eo
aut ra
ss c
Specified torques
ce
e
nl
pt
du
an
♦ ⇒ “5.1.1 Assembly overview - tail lights, rear wing doors”, page
itte
y li
163 .
erm
ab
ility
ot p
wit
, is n
5.8.2 Removing and installing turn signal bulb
h re
hole
-M6- / -M8- , rear lid
spec
es, in part or in w
t to the co
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
185
AG.
5. Tail lights
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove bulb holder ⇒ page 168 .
– Pull out turn signal bulbs -1- in a straight line from bulb carrier
-5-.
Turn signal bulb -M6- / -M8- : 12V, WY16W agen
AG. Volkswagen AG d
oes
olksw not
Installing d by V gu
ara
rise nte
Install in the reverse order of removal.
autho
When doing this, note the eo
ra
following: ss c
ce
le
un
pt
an
d
itte
Caution
y li
erm
ab
ility
ot p
Risk of damage to the bulb.
wit
is n
h re
♦ Do not touch the glass part of the bulb with bare fingers.
ole,
spec
Fingers leave traces of grease on the glass bulb, which
urposes, in part or in wh
evaporate when the bulb is switched on and cause the
t to the co
glass bulb to cloud over.
♦ Wear clean fabric gloves when inserting bulbs.
rrectne
Specified torques
ss o
cial p
f
♦ ⇒ “5.1.2 Assembly overview - tail lights, rear lid”, page 165 .
inform
mer
atio
5.8.3 Removing and installing turn signal bulb
om
n
c
i
-M6- / -M8- , rear lid (LED)
or
n thi
te
sd
iva
Special tools and workshop equipment required
pr
cum
r
fo
en
ng
♦ Torque wrench - V.A.G 1783-
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove tail light ⇒ page 169 .
186 Rep. gr.94 - Lights, bulbs, switches - exterior
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
California
aut 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 r a ➤ , Transporter 20 ...
c
s
s Electrical system - Edition 04.2019
ce
le
un
pt
an
d
itte
– Turn bulb holder anti-clockwise in direction of -arrow- and pull
y li
erm
ab
out turn signal bulb -2- from tail light housing -3-.
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
– Pull out turn signal bulb -2- in a straight line from bulb holder
atio
-1-.
om
n
c
i
Turn signal bulb -M6- / -M8- : 12V, WY16 W
or
n thi
te
sd
va
Installing
i
o
pr
cum
r
fo
Install in the reverse order of removal. When doing this, note the
en
ng
t.
yi
following:
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
Caution by c lksw
cted agen
Prote AG.
Risk of damage to the bulb.
♦ Do not touch the glass part of the bulb with bare fingers.
Fingers leave traces of grease on the glass bulb, which
evaporate when the bulb is switched on and cause the
glass bulb to cloud over.
♦ Wear clean fabric gloves when inserting bulbs.
Specified torques
♦ ⇒ “5.1.3 Assembly overview - tail lights, rear lid (LED)”,
page 166 .
5.8.4 Removing and installing turn signal bulb
-M6- / -M8- , dropside
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
5. Tail lights 187
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se te
o
California 2016 ➤ , Caravelle 2016
auth ➤ , Multivan 2016 ➤ , Transporter 20 ... e or a
c
Electrical system - Edition 04.2019 ss
ce
le
un
pt
an
d
– Unscrew securing bolts -1- of lens -2-.
itte
y li
erm
ab
– Push turn signal bulb -4- into holder, turn it anti-clockwise, and
ility
ot p
pull it out of bulb carrier -3-.
wit
is n
h re
ole,
Rear left turn signal bulb - M6- or rear right turn signal bulb - M8- :
spec
12V, P 21 W
urposes, in part or in wh
t to the co
Installing
Install in the reverse order of removal. When doing this, note the
rrectne
following:
s
Caution
s o
cial p
f inform
Risk of damage to the bulb.
mer
atio
♦ Do not touch the glass part of the bulb with bare fingers.
om
n
Fingers leave traces of grease on the glass bulb, which
c
i
or
n thi
evaporate when the bulb is switched on and cause the
te
sd
a
glass bulb to cloud over.
iv
o
pr
cum
r
fo
♦ Wear clean fabric gloves when inserting bulbs.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
– On assembly, rubber seal of scatter lens must be installed in‐
by lksw
cted agen
Prote
wards in lower corners of light -arrows- to act as water drain
AG.
aperture.
Specified torques
♦ ⇒ “5.1.4 Assembly overview - tail lights, dropside vehicles”,
page 167 .
188 Rep. gr.94 - Lights, bulbs, switches - exterior
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Electrical system - Edition 04.2019
6 High-level brake light
⇒ “6.1 Removing and installing high-level brake light”,
page 189
⇒ “6.2 Removing and installing high-level brake light”,
page 191
6.1 Removing and installing high-level
brake light
⇒ “6.1.1 Removing and installing high-level brake light, vehicles
with rear lid”, page 189
⇒ “6.1.2 Removing and installing high-level brake light, vehicles
with rear wing doors”, page 190
6.1.1 Removing and installing high-level
brake light, vehicles with rear lid
n AG. Volkswagen A ge G do
swa es n
Special tools and workshop equipment
by
Vol required
k ot g
ua
d ran
se
♦ Plastic wedge - T10039/1-
tho
ri tee
or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
– Switch off ignition and all electrical equipment and then re‐
nform
ercia
move ignition key.
m
at
om
io
Caution
n
c
in t
or
his
ate
Danger of damage to component surfaces.
do
priv
cum
or
♦ When working with leverage tools, always mask off the
f
en
ng
t.
components installed in visible areas using commercially
yi Co
op
available adhesive tape.
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co lksw
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Prote
– Attach a strip of adhesive tape -1- to the area of the rear lid
AG.
above the high-level brake light.
Note
The high-level brake light cannot be removed without permanent‐
ly damaging it and must be renewed following removal ⇒ Elec‐
tronic parts catalogue (ETKA) .
6. High-level brake light 189
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Electrical system - Edition 04.2019
– Insert wedge - T10039/1- -1- at top between high-level brake
light -2- and rear lid.
AG. Volkswagen
– Using plastic wedge - T10039/1-wage-1-, press high-level
n AG do
ebrake
s no
olks
light -2- downwards. d by V t gu
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e ran
ris tee
tho or
au ac
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nl
pt
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ab
ility
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wit
, is n
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hole
spec
– Swing high-level brake light -2- out of rear lid.
es, in part or in w
t to the co
– Release and disconnect electrical connector -1-.
– Remove high-level brake light.
rrectness of i
Installing
l purpos
When installing high-level brake light, make sure seal is correctly
seated. The seal must not form loops or be damaged.
nform
ercia
– Connect connector and engage it.
m
at
om
io
– Press high-level brake light into rear lid.
n
c
in t
or
his
e
– Engage locking devices at top.
at
do
priv
– Engage retaining springs at bottom.
um
for
en
ng
t.
yi
– Check proper operation of high-level brake light bulb - M25- .
Co
Cop py
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rig ht
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6.1.2 Removing and installing high-level
co Vo
by lksw
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Prote
brake light, vehicles with rear wing doors
AG.
Note
The high-level brake light bulb - M25- is divided for vehicles with
rear wing doors. When ordering spare parts, note the respective
vehicle side.
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
190 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Unscrew both securing bolts -2- of high-level brake light -1-.
– Remove high-level brake light. AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Release connector and pull it off in -direction of arrow-.
nf
ercia
or
– Remove high-level brake light - M25- .
m
m
atio
m
Installing
o
n in
or c
thi
e
Install in the reverse order of removal. When doing this, note the
t
sd
iva
following:
o
r
rp
cu
o
m
f
en
Specified torques
ng
t.
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Cop py
Component Specified torque
t. rig
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pyri by
Vo
o
High-level brake light bulb - M25- to 1.5 Nm
c by lksw
cted agen
body
Prote AG.
6.2 Removing and installing high-level
brake light
Note
♦ Failure of light-emitting diodes in high-level brake lights
♦ The individual light-emitting diodes (LEDs) in the high-level
brake lights are comprised in groups of 3 LEDs and supplied
with current in groups.
♦ Due to the failure of individual LEDs, the intact LEDs of the
group in question are placed under increased strain and it
must therefore be anticipated that further LED will soon fail as
well.
♦ If an LED group (3 individual light-emitting diodes) fails, the
legal light values of the ECE ruling (ECE = Economic Com‐
mission for Europe) are still complied with.
♦ If more than 3 individual LEDs fail, the legal light values of the
ECE ruling are no longer complied with and the light for the
high-level brake must be renewed.
The LEDs in the high-level brake light cannot be renewed indi‐
vidually. In the event of repairs, the high-level brake light bulb -
M25- must be renewed as a complete unit.
– ⇒ “6.1.1 Removing and installing high-level brake light, vehi‐
cles with rear lid”, page 189 .
6. High-level brake light 191
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Electrical system - Edition 04.2019
– ⇒ “6.1.2 Removing and installing high-level brake light, vehi‐
cles with rear wing doors”, page 190 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
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ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
192 Rep. gr.94 - Lights, bulbs, switches - exterior
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Electrical system - Edition 04.2019
7 Number plate light
⇒ “7.1 Removing and installing number plate light X4 / X5 ”, page
193
⇒ “7.2 Removing and installing
agebulb
n AG.for
Volnumber
kswagen Aplate
G do light X4 / X5
es n
”, page 195 olksw ot g
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7.1 Removing and installing number plate
r tee n
ho
ut or
light -X4- / -X5-
a ac
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nl
pt
du
⇒ “7.1.1 Removing and installing number plate light, rear lid or
an
itte
y li
rear wing door”, page 193
erm
ab
ility
ot p
⇒ “7.1.2 Removing and installing number plate light, rear lid or
wit
, is n
rear wing door (LED)”, page 194
h re
hole
⇒ “7.1.3 Removing and installing number plate light, dropside ve‐
spec
es, in part or in w
hicles”, page 194
t to the co
7.1.1 Removing and installing number plate
light, rear lid or rear wing door
rrectness of i
The removal and installation procedure for both number plate
l purpos
lights is carried out in the same way and is only described for one
light.
nform
ercia
Removing
m
at
om
i
– Switch off ignition and all electrical equipment and then re‐
on
c
move ignition key. in t
or
his
ate
do
riv
– Unscrew securing bolts -arrows- for number plate light - X- .
p
cum
for
– Remove number plate light - X- .
en
ng
t.
yi Co
op
Installing
C py
t. rig
gh ht
yri by
Install in the reverse order of removal. When doing this, note the cop Vo
by lksw
cted
following:
agen
Prote AG.
Note
On the scatter lens of the number plate light - X- is a small silver
coloured anti-dazzle strip -arrow-. When installing the lens, al‐
ways make sure that the anti-dazzle strip faces the bumper.
7. Number plate light 193
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Electrical system - Edition 04.2019
7.1.2 Removing and installing number plate
light, rear lid or rear wing door (LED)
Note
The lighting element of the number plate light - X- has light-emit‐
ting diodes and cannot be renewed individually. If damaged,
entire number plate light must be renewed.
Removing
– Switch off ignition and all electrical consumers, and withdraw
ignition key. AG. Volkswagen AG do gen
es n swa
– Turn light switch to “0” bposition.
yV
olk ot g
ua
ed ran
is
– Push number plate thorlight in direction of -arrow- using a suitable tee
or
screwdriver ands remove from installation opening.
au ac
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Release and separate electrical connector -1- on number plate
l purpos
light - X- -2-.
Installing
nform
ercia
Install in the reverse order of removal. When doing this, note the
m
following:
com
tion in
r
– Reconnect connector, must engage audibly.
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
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rig ht
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co Vo
by lksw
cted agen
– First insert number plate light with spring clip in installation
Prote AG.
opening in direction of -arrow 1- and then engage securely in
direction of -arrow 2-.
– Perform functional check.
7.1.3 Removing and installing number plate
light, dropside vehicles
The removal and installation procedure for both number plate
lights - X- is carried out in the same way and is only described for
one light.
194 Rep. gr.94 - Lights, bulbs, switches - exterior
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
California 2016 ➤ hori,
s Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter
nte
eo 20 ...
aut Electrical system - Edition ra 04.2019
ss c
ce
le
un
pt
Removing
an
d
itte
y li
– Switch off ignition and all electrical equipment and then re‐
rm
ab
pe
ility
move ignition key.
ot
wit
, is n
– Unscrew securing bolt -3- for cover cap with lens.
h re
hole
spec
– Remove protective cap with lens -1-.
es, in part or in w
t to the co
– Pull off connectors.
– Unscrew securing bolts -4- and remove lower part of housing.
rrectness of i
Installing
l purpos
Installation is carried out in the reverse sequence of removal.
nform
mercia
a
com
tion in
r
te o
thi
7.2 Removing and installing bulb for number
s
iva
do
r
rp
plate light - X4- / -X5-
cum
fo
en
ng
t.
yi Co
⇒ “7.2.1 Removing and installing bulb for number plate light, rear Cop py
lid or rear wing door”, page 195 ht. rig
rig ht
py by
co Vo
⇒ “7.2.2 Removing and installing bulb for number plate light, rear
by lksw
cted agen
Prote
lid or rear wing door (LED)”, page 196
AG.
⇒ “7.2.3 Removing and installing bulb for number plate light,
dropside vehicles”, page 196
7.2.1 Removing and installing bulb for number
plate light, rear lid or rear wing door
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove number plate light ⇒ page 193 .
– Press contact plate -1- in -direction of arrow- and remove bulb
-2- from bulb holder.
Bulb for number plate light - X- : festoon bulb, 12V, 5 W
Installing
Install in the reverse order of removal. When doing this, note the
following:
Caution
Risk of damage to the bulb.
♦ Do not touch the glass part of the bulb with bare fingers.
Fingers leave traces of grease on the glass bulb, which
evaporate when the bulb is switched on and cause the
glass bulb to cloud over.
♦ Wear e.g. clean fabric gloves when inserting bulbs.
7. Number plate light 195
California 2016 ➤ , Caravelle 2016 n AG➤
. Vo, lkMultivan
swagen AG2016 ➤ , Transporter 20 ...
wage does
Electrical system - Edition
yV
o 04.2019
lks not
g b ua
ed ran
oris tee
th or
au ac
Note ss
ce
le
un
pt
an
d
On the scatter lens of the number plate light - X- is a small silver
itte
y li
rm
coloured anti-dazzle strip -arrow-. When installing the lens, al‐
ab
pe
ility
ways make sure that the anti-dazzle strip faces the bumper.
ot
wit
, is n
h re
– Perform functional check.
hole
spec
es, in part or in w
t to the co
rrectness of i
7.2.2 Removing and installing bulb for number
l purpos
plate light, rear lid or rear wing door
nform
ercia
(LED)
m
a
com
tion in
Note
r
te o
thi
s
iva
do
r
The lighting element of the number plate light - X- has light-emit‐
rp
cum
fo
ting diodes and cannot be renewed individually. In the event of
en
ng
t.
yi
damage, the entire number plate light must be renewed
Co
op py
⇒ page 194 . t. C rig
gh ht
pyri by
Vo
co lksw
by
7.2.3 Removing and installing bulb for number
cted agen
Prote AG.
plate light, dropside vehicles
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Unscrew securing bolt -3- for cover cap with lens.
– Push bulb -2- into holder, turn it anti-clockwise and pull it out
of bulb holder.
Bulb for number plate light - X- : festoon bulb, 12V, P 5 W
Installing
Install in the reverse order of removal. When doing this, note the
following:
Caution
Risk of damage to the bulb.
♦ Do not touch the glass part of the bulb with bare fingers.
Fingers leave traces of grease on the glass bulb, which
evaporate when the bulb is switched on and cause the
glass bulb to cloud over.
♦ Wear e.g. clean fabric gloves when inserting bulbs.
– Perform functional check.
196 Rep. gr.94 - Lights, bulbs, switches - exterior
AG. Volkswagen AG d
agen o
California
Vol
ksw 2016 ➤ , Caravelle 2016
es n
ot g➤ , Multivan 2016 ➤ , Transporter 20 ...
d by ua
ran Electrical system - Edition 04.2019
se
ri t ee
tho or
s au ac
s
8 Steering column switch module
ce
le
un
pt
an
d
itte
y li
⇒ “8.1 Assembly overview - steering column switch module”, page erm
ab
197
ility
ot p
wit
⇒ “8.2 Removing and installing steering column electronics con‐
is n
h re
trol unit J527 ”, page 198
ole,
spec
urposes, in part or in wh
⇒ “8.3 Removing and installing steering column combination
t to the co
switch”, page 199
⇒ “8.4 Removing and installing steering column switch module”,
page 200
rrectne
⇒ “8.5 Removing and installing ignition/starter switch”,
s
page 201
s o
cial p
f i
⇒ “8.6 Removing and installing lock cylinder”, page 202
nform
mer
⇒ “8.7 Removing and installing steering lock housing”,
atio
m
page 204
o
n
c
i
or
n thi
8.1 Assembly overview - steering column switch module
te
sd
iva
o
pr
cum
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fo
en
ng
1 - Steering column
t.
yi Co
Cop py
t. rig
2 - Bolt opyri
gh by
Vo
ht
❑ Qty. 2
c by lksw
cted agen
Prote AG.
❑ For securing steering
lock housing to steering
column
❑ Shear bolts
3 - Clamping piece
❑ Means of securing
switch module to steer‐
ing column
4 - Steering column combina‐
tion switch - E595-
❑ Removing and installing
⇒ page 199
5 - Clamping screw
❑ For securing switch
module to steering col‐
umn
❑ 3 Nm
6 - Steering column electronics
control unit - J527-
❑ With airbag coil connec‐
tor and return ring with
slip ring - F138-
❑ Removing and installing
⇒ page 198
7 - Steering lock housing
❑ Removing and installing
steering lock housing
⇒ page 204
❑ Removing and installing
ignition switch
⇒ page 201
8. Steering column switch module 197
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Electrical system - Edition 04.2019
8 - Lock cylinder
❑ Removing and installing ⇒ page 202
9 - Immobiliser reader coil
❑ Part of lock cylinder and can only be removed together with lock cylinder
8.2 Removing and installing steering col‐
umn electronics control unit - J527-
Note
AG. Volkswagen AG d
agen oes
ksw
♦ Risk of damage to the electronic components by due
Vol
to electro‐ not
gu
static discharge. rised ara
nte
ho eo
ut
♦ Before disconnecting the electrical connector,
s a the mechanic ra
c
must electrostatically discharge himself or herself by briefly
s
ce
le
grasping hold of door striker plate or similar.
un
pt
an
d
itte
y li
erm
ab
Removing
ility
ot p
wit
– Bring front wheels to straight-ahead position.
is n
h re
ole,
– Move steering wheel to rearmost and lowest position. Use the
spec
urposes, in part or in wh
full range of the steering column adjustment for this purpose.
t to the co
– Remove steering wheel ⇒ Running gear, axles, steering; Rep.
gr. 48 ; Steering wheel; Removing and installing steering
wheel .
rrectne
– Remove lower steering column trim ⇒ General body repairs,
s
interior; Rep. gr. 68 ; Compartments and covers; Removing
s o
and installing lower steering column trim .
cial p
f inform
– Unclip steering column electronics control unit - J527- -1- in
mer
-direction of arrow- by releasing locking lugs -2-.
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
198 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Unclip steering column electronics control unit - J527- -1- in
-direction of arrow- by releasing locking lugs -2-. While doing
this, disconnect electrical connector -arrow-.
– Detach steering column electronics control unit - J527- -1-.
Installing
AG. Volkswagen AG d
Install in the reverse order of removal, observing the
lksw
following:
agen oes
not
o
yV gu
edb ara
ris nte
Note tho eo
au ra
c
ss
ce
le
If the control unit is renewed, perform the adaptation routines us‐
un
pt
an
d
ing ⇒ Vehicle diagnostic tester.
itte
y li
rm
ab
pe
ility
– If a new steering column electronics control unit - J527- is in‐
ot
wit
, is n
stalled, do not remove transport protection until steering wheel
h re
is mounted.
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
In the event of a warranty or goodwill claim, the transportation lock
or locking device for the return ring must be inserted into the
l purpos
component causing the damage immediately after removal. With‐
out the lock/locking device, analysis by the manufacturer/supplier
is not possible. In the event of non-compliance, the warranty re‐
nform
ercia
serves the right to cancel the request.
m
a
com
tion in
r
8.3 Removing and installing steering col‐
te o
thi
s
iva
umn combination switch
do
r
rp
cum
fo
en
g
Special tools and workshop equipment required
n
t.
yi Co
Cop py
♦ Torque wrench - V.A.G 1783- ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
The following components are integrated in the steering column
combination switch - E595- :
♦ Windscreen wiper switch - E-
♦ Turn signal switch - E2-
♦ Rear window wiper switch - E34-
♦ Intermittent wiper regulator - E38-
Note
If one of the switches is defective, the steering column combina‐
tion switch - E595- must be renewed as a complete unit.
8. Steering column switch module 199
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Electrical system - Edition 04.2019
Removing
– Remove steering column electronics control unit - J527-
⇒ page 198 .
– Loosen bolt -2-.
– Remove steering column combination switch - E595- -1- in
-direction of arrow-.
Installing
Install in the reverse order of removal, observing the following:
Specified torques
♦ ⇒ “8.1 Assembly overview - steering column switch module”,
page 197
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b ara
8.4 Removing and installing steering col‐
d
rise nte
tho eo
umn switch module ss au ra
c
ce
le
un
Special tools and workshop equipment required
pt
an
d
itte
y li
♦ Torque wrench - V.A.G 1783-
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
Removing
com
tion in
r
– Disconnect battery ⇒ page 7 .
te o
thi
s
iva
do
– Remove steering wheel ⇒ Running gear, axles, steering; Rep.
r
rp
cum
gr. 48 ; Steering wheel; Removing and installing steering
fo
en
g
wheel .
n
t.
yi Co
Cop py
t.
– Remove steering column trim ⇒ General body repairs, interior;
rig
gh ht
yri by
Rep. gr. 68 ; Compartments/covers; Assembly overview - cop Vo
by lksw
steering column trim . cted agen
Prote AG.
– Remove return ring with slip ring (coil connector)
⇒ page 198 .
200 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Unscrew clamp bolt -arrow- on steering column switch mod‐
ule.
Note
The connector catch on the steering column switch module runs
in a quadrant in the housing. When pulling out the steering column
switch module, there may be a requirement to pull the locking
lever up again to enable the connector to slide easily out of the
quadrant.
– To release the catch, pull up locking lever on connector on
steering column switch module in -direction of arrow-.
– Pull steering column switch module out of contact connector
housings and remove it.
Installing
Install in the reverse order of removal. When doing this, note the
following:
– Push steering column switch module onto steering column as
far as it will go and align straight.
– Tighten clamping bolt -arrow- on steering column switch mod‐
ule.
Specified torques
♦ ⇒ “8.1 Assembly overview - steering column switch module”,
page 197
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
8.5 Removing and installing ignition/starter
ility
ot p
wit
, is n
switch
h re
hole
spec
Removing
es, in part or in w
t to the co
– Disconnect battery ⇒ page 7 .
– Remove steering column trim ⇒ General body repairs, interior;
rrectness of i
Rep. gr. 68 ; Compartments/covers; Assembly overview -
steering column trim .
l purpos
Note
nform
mercia
at
♦ The illustrations below are only schematic illustrations and
om
io
specific details may vary.
n
c
in t
or
his
e
♦ For reasons of clarity, the ignition/starter switch is shown with‐
at
do
riv
out steering wheel and steering column switch module in the
p
cum
or
illustrations below.
f
en
ng
t.
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Cop py
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rig ht
py by
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by lksw
cted agen
Prote AG.
8. Steering column switch module 201
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Californiaaut 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤
ho e o , Transporter
ra 20 ...
Electrical system - Edition 04.2019
ss c
ce
e
nl
pt
du
an
– Pull out primary locking element -1- of connector in itte
y li
-direction of arrow A-.
erm
ab
ility
ot p
– Press primary locking element -1- and pull connector -2- in
wit
, is n
-direction of arrow B- off ignition/starter switch - D- -3-.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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ercia
orm
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atio
om
n in
or c
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t.
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op
– Remove anti-tamper paint from both clamping bolts -A-. C py
t. rig
gh ht
yri
– Loosen clamping bolts -A- slightly and pull ignition/starter
p by
co Vo
by lksw
switch - D- -1- in -direction of arrow- out of steering lock hous‐ Prote
cted AG.
agen
ing.
Installing
Install in the reverse order of removal. When doing this, note the
following:
Caution
When installing the ignition/starter switch, ensure that the ig‐
nition/starter switch and the lock cylinder are in the same
position, e.g. “ignition on”.
– Turn ignition key in lock cylinder to “Ignition ON” position.
– Push ignition/starter switch into steering lock housing to stop.
– Tighten clamping bolts and seal with anti-tamper paint.
– Push connector onto ignition/starter switch and push in pri‐
mary locking element.
– Install steering column trim ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers; Assembly overview -
steering column trim .
8.6 Removing and installing lock cylinder
Caution
♦ The steering lock could be destroyed.
♦ If the steering lock is actuated without lock cylinder, it will
block and must be renewed.
♦ The steering lock must not be actuated without lock cylin‐
der.
202 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical
AG. Volkswagen A system - Edition 04.2019
n G do
wage es n
Volks ot g
Removing ed
by ua
ran
oris tee
– Disconnect battery ⇒ page 7 . au
th or
ac
ss
– Remove steering column trim ⇒ General body repairs, interior;
ce
le
un
pt
Rep. gr. 68 ; Compartments/covers; Assembly overview -
an
d
itte
steering column trim .
y li
erm
ab
ility
– Release connector -arrow- of immobiliser reader coil on lock
ot p
wit
cylinder and carefully pull it off.
is n
h re
ole,
spec
urposes, in part or in wh
Note
t to the co
The immobiliser reading coil is secured to the lock cylinder and
cannot be renewed individually.
rrectne
– Insert ignition key in lock cylinder and turn to position “Drive”.
ss o
cial p
Positions for key in lock cylinder:
f inform
mer
1- Position “Stop”
atio
m
2- Position “Drive”
o
n
c
i
or
n thi
e
3- Position “Start”
t
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pr
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fo
– Insert a piece of steel wire (approx. 1.2 mm in diameter) in
en
ng
t.
yi
drilling next to ignition key -arrow-.
Co
Cop py
ht. rig
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py by
co Vo
Note
by lksw
cted agen
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♦ In order to ensure that the steel wire is inserted straight into
the hole, it may be necessary to dismantle the ignition key and
insert key into lock cylinder without key head ⇒ General body
repairs, exterior; Rep. gr. 57 ; Central locking; Overview of
fitting locations - central locking .
♦ If possible, use the so-called “workshop key”. This has a small‐
er head and there is no requirement for it to be dismantled.
8. Steering column switch module 203
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Release lock cylinder securing lever using steel wire -arrow-
and remove lock cylinder from steering lock housing.
1- Lock cylinder
2- Steel wire (approx. 1.2 mm diameter)
3- Securing lever
Installing
– Insert ignition key in lock cylinder and turn to position “Drive”.
– Release securing lever using a piece of steel wire (approx.
1.2 mm diameter) and insert lock cylinder in steering lock
housing.
Note
When installing lock cylinder, ensure that connection for immo‐ . Volkswagen AG
biliser reader coil is in guide of steering lock housing. swa
gen AG does
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– Pull piece of steel wire out of lock cylinder and check
ho
ris that lock nte
eo
cylinder is seated properly in steering lock housing.
aut ra
c
ss
ce
e
nl
pt
– Connect immobiliser reader coil connector -arrow- to lock cyl‐
du
an
itte
inder and engage it.
y li
erm
ab
ility
– Install steering column trim ⇒ General body repairs, interior;
ot p
Rep. gr. 68 ; Compartments/covers; Assembly overview -
wit
, is n
h re
steering column trim .
hole
spec
es, in part or in w
t to the co
Note
In the event of complaints regarding the lock cylinder or the steer‐
rrectness of i
ing lock, it is imperative that the corresponding key is also provi‐
ded if a warranty or goodwill claim is made. Without the key, no
l purpos
analysis can be carried out for the steering lock or lock cylinder
by the manufacturer/supplier and the invoice will not be covered
nf
ercia
by the warranty. In the event of non-compliance, the warranty re‐
or
serves the right to cancel the request. The purchase costs for the
m
m
new key can be submitted with the request. atio
om
n in
or c
thi
te
sd
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8.7 Removing and installing steering lock
iv
o
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cu
o
housing
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t.
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Cop py
t. rig
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yri by
Note
op Vo
by c lksw
cted agen
Prote AG.
To remove the steering lock housing, the shear bolts of the steer‐
ing column switch must be drilled out. New shear bolts are re‐
quired for subsequent installation ⇒ ETKA (electronic parts
catalogue) .
Removing
– Disconnect battery ⇒ page 7 .
– Remove steering column switch module ⇒ page 200 .
204 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical
olksw
system - Edition 04.2019
AG. V agen AG
agen does
olksw not
yV gu
db ara
WARNING rise nte
tho eo
au ra
c
Danger of eye injury from drilling swarf. ss
ce
e
nl
pt
du
When drilling out, swarf may fly off and cause eye injury.
an
itte
y li
erm
ab
Wear safety goggles.
ility
ot p
wit
, is n
h re
– Drill out shear-head bolts -arrows-.
hole
spec
es, in part or in w
– Remove steering lock housing.
t to the co
If steering lock housing is to be renewed, further steps may be
necessary:
rrectness of i
– Remove lock cylinder ⇒ page 202 .
l purpos
– Remove ignition/starter switch - D- ⇒ page 201 .
Installing
nform
mercia
at
om
i
Caution
on
c
in t
or
his
e
Steering lock will be damaged if improperly fitted!
at
do
priv
cum
Failure to follow instructions will result in damage to the steer‐
for
en
g
ing lock when the shear-head bolts are tightened.
n
t.
yi Co
Cop py
Before fitting the steering lock housing to the steering column,
t. rig
gh ht
yri
the ignition key must be turned in the lock cylinder to the “Ig‐
p by
o Vo
by c lksw
nition ON” position. Prote
cted AG.
agen
– Fit steering lock housing with new shear-head bolts -arrows-
to steering column.
– Tighten shear-head bolts until the heads shear off.
– Install steering column switch module ⇒ page 200 .
If the steering lock housing has been renewed:
– Install lock cylinder ⇒ page 202 .
– Install ignition/starter switch - D- ⇒ page 201 .
Note
In the event of complaints regarding the lock cylinder or the steer‐
ing lock, it is imperative that the corresponding key is also provi‐
ded if a warranty or goodwill claim is made. Without the key, no
analysis can be carried out for the steering lock or lock cylinder
by the manufacturer/supplier and the invoice will not be covered
by the warranty. In the event of non-compliance, the warranty re‐
serves the right to cancel the request. The purchase costs for the
new key can be submitted with the request.
8. Steering column switch module 205
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
9 Parking aid
⇒ “9.1 Assembly overview – parking aid”, page 206
⇒ “9.2 Removing and installing parking aid control unit J446 ”,
page 207
⇒ “9.3 Removing and installing front parking aid warning buzzer
H22 ”, page 208
n AG. Volkswagen AG do
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⇒ “9.4 Removing and installing warning buzzer 2 for rear parking
yV
olks ot g
ua
aid H31 ”, page 210 ed b ran
oris tee
h
⇒ “9.5 Adjusting volume and frequency of warning
s au buzzer 2 for
t or
ac
rear parking aid H31 ”, page 212 s
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nl
pt
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⇒ “9.6 Removing and installing front parking aid senders”,
an
itte
y li
page 212
erm
ab
ility
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⇒ “9.7 Removing and installing rear parking aid senders”,
wit
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page 213
h re
hole
spec
9.1 Assembly overview – parking aid
es, in part or in w
t to the co
1 - Parking aid button - E266-
rrectness of i
❑ With parking aid switch
illumination bulb - L117-
l purpos
❑ With parking aid warn‐
ing lamp - K136-
nform
ercia
❑ Installed in switch unit in
middle section of dash
m
at
om
panel
ion
c
in t
r
❑ Removing and installing
o
his
te
⇒ page 253
a
do
priv
cum
or
2 - Warning buzzer 2 for rear
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parking aid - H31-
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❑ Only on vehicles equip‐
. C rig
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rig
ped with front and rear py by
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parking aid
by lksw
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Prote AG.
❑ Fitting location on LHD
vehicles: behind right B-
pillar trim
❑ Fitting location on RHD
vehicles: behind left B-
pillar trim
❑ Fitting location on Multi‐
van with loudspeaker
system: behind rear left
loudspeaker
❑ Fitting location on Multi‐
van without loudspeak‐
er system: on rear left D-
pillar
❑ Adjusting volume of
warning buzzer 2 for
rear parking aid - H31-
⇒ page 212
❑ Warning buzzer 2 for
rear parking aid - H31-
discontinued as of Octo‐
ber 2018
❑ Removing and installing ⇒ page 210
206 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
3 - Rear parking aid senders
❑ Rear left parking aid sender - G203-
❑ Rear left centre parking aid sender - G204-
❑ Rear right centre parkingwaaid gensender
AG. Volks-wG205-
agen AG
does
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❑ Rear right parkingd baid
y V sender - G206-
o gu
ara
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❑ Installed in rear
horis
bumper. eo
ut ra
❑ Removingssand installing ⇒ page 213
a c
ce
le
un
4 - Parking aid control unit - J446-
pt
an
d
itte
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❑ Fitting location in driver footwell, on side of retainer of onboard supply control unit
erm
ab
❑ Removing and installing ⇒ page 207
ility
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wit
is n
5 - Front parking aid warning buzzer - H22-
h re
ole,
❑ Fitting location in driver footwell, on side of retainer of onboard supply control unit
spec
urposes, in part or in wh
❑ Removing and installing ⇒ page 208
t to the co
6 - Front parking aid senders
❑ Front right parking aid sender - G252-
rrectne
❑ Front centre right parking aid sender - G253-
s
❑ Front centre left parking aid sender - G254-
s o
cial p
f
❑ Front left parking aid sender - G255-
inform
❑ Installed in front bumper.
mer
atio
m
❑ Removing and installing ⇒ page 212
o
n
c
i
or
n thi
te
sd
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9.2 Removing and installing parking aid
p
cum
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fo
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ng
control unit - J446-
t.
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pyri by
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by c lksw
Note Prote
cted AG.
agen
Parking aid control unit - J446- is secured in driver footwell to side
of onboard supply control unit retainer.
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove driver footwell cover ⇒ General body repairs, interior;
Rep. gr. 70 ; Dash panel; Assembly overview - dash panel .
– Remove dash panel end cover on left side ⇒ General body
repairs, interior; Rep. gr. 70 ; Dash panel; Assembly overview
- dash panel .
– Remove bonnet release lever ⇒ General body repairs, exte‐
rior; Rep. gr. 55 ; Bonnet; Removing and installing bonnet
release lever .
– Lift floor covering at A-pillar in driver footwell, and fold it aside.
9. Parking aid 207
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
. Volkswagen AG
Electrical system - Edition 04.2019 swa
gen AG does
k not
Vol gu
d by ara
– Move clear area around parking aid control unit - J446- -1-.orise nte
th eo
– au
Disconnect electrical connectors on relay and fuse carrier,
ra
ss and c
lay them aside.
ce
e
nl
pt
du
an
– Suspend wiring harness for door wiring harness in area of
itte
y li
parking aid control unit - J446- -1- on the side.
erm
ab
ility
ot p
– Press release button -2-, and remove parking aid control unit
wit
, is n
- J446- -1- from onboard supply control unit bracket -3-.
h re
hole
spec
– Release and disconnect electrical connectors -4-.
es, in part or in w
t to the co
rrectness of i
Installing
l purpos
Install in the reverse order of removal. When doing this, note the
following:
nf
ercia
o
– Attach and engage electrical connectors -4-.
rm
m
atio
m
– Push parking aid control unit - J446- -1- into onboard supply
o
n in
c
control unit bracket -3-, and engage it.
or
thi
te
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iva
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ng
t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted
9.3 Removing and installing front parking
agen
Prote AG.
aid warning buzzer - H22-
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-
208 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
Removing
. Volkswagen AG
gen AG207 .
– Remove parking aid control unit - J446-ks⇒wapage does
ol not
y V gu
– Move clear area around front parking
ised b aid warning buzzer - ara
nte
H22- -3-. ut
hor eo
a ra
s c
– Suspend wiring harness fors door wiring harness in area of front
ce
e
parking aid warning buzzer - H22- -3- on the side.
nl
pt
du
an
itte
y li
– Disconnect electrical connector -2-.
erm
ab
ility
ot p
– Unscrew rear bolt -3-.
wit
, is n
h re
– Swing front parking aid warning buzzer - H22- -1- downwards.
hole
spec
– Unscrew front bolt -3-.
es, in part or in w
t to the co
– Remove front parking aid warning buzzer - H22- -1-.
rrectness of i
Note
l purpos
♦ The best way to loosen bolts -3- is from below through the
driver footwell.
nform
ercia
♦ Depending on the equipment, spreader rivets may be installed
m
at
om
instead of bolts -3-.
ion
c
in t
or
his
ate
do
riv
Installing
p
cum
for
Install in the reverse order of removal observing the following:
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note
op Vo
by c lksw
cted agen
Prote AG.
Secure bolts -3- with butyl adhesive sealing cord or a magnetic
tool to prevent them from being lost.
– Fit rear bolt -3- with front parking aid warning buzzer - H22-
-1-, and screw it in to stop.
– Swing front parking aid warning buzzer - H22- -1- upwards into
installation position.
– Screw in front bolt -3- to stop.
– Tighten bolts -3-.
– Connect electrical connector -2-.
Specified torques
Component Specified torque
Bolts of front parking aid warning buzzer - H22- 4 Nm
9. Parking aid 209
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
9.4 Removing and installing warning buzzer
2 for rear parking aid - H31-
⇒ “9.4.1 Removing and installing warning buzzer 2 for rear park‐
ing aid H31 ”, page 210
⇒ “9.4.2 Removing and installing warning buzzer 2 for rear park‐
ing aid H31 , Multivan”, page 210
9.4.1 Removing and installing warning buzzer
2 for rear parking aid - H31-
Removing
Note
♦ The warning buzzer 2 for rear parking aid - H31- has been
discontinued as of October 2018. Sound signals are now out‐
put via the front parking aid warning buzzer - H22- . Distin‐
guishing feature is the tone pitch.
♦ On vehicles equipped with a parking aid at the rear only, warn‐
ing buzzer 2 for rear parking aid - H31- is not featured.
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove upper B-pillar trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Trims, interior; Overview of fitting locations - in‐
terior trims .
– Separate electrical connector -arrow-.
– Loosen spreader rivets, and detach warning buzzer 2 for rear
parking aid - H31- -1-.
Installing
Install in reverse order of removal.
AG. Volkswagen AG d
agen oes
lksw not
9.4.2 Removing and installing warning buzzer Vo gu
d by ara
ise nte
2 for rear parking aid - H31- , Multivan or eo
h
aut ra
ss c
Special tools and workshop equipment required
ce
le
un
pt
an
d
♦ Torque wrench - V.A.G 1783-
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
yri by
210
op Vo
by c lksw
Rep. gr.94 - Lights, bulbs, switches - exterior Prote
cted AG.
agen
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
Removing
Note
♦ The warning buzzer 2 for rear parking aid - H31- has been
discontinued as of October 2018. Sound signals are now out‐
put via the front parking aid warning buzzer - H22- . Distin‐
guishing feature is the tone pitch.
♦ On vehicles equipped with a parking aid at the rear only, warn‐
ing buzzer 2 for rear parking aid - H31- is not featured.
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
“California” model only
– Remove rear left cupboard ⇒ General body repairs - Califor‐
nia; Rep. gr. 77 ; Interior fittings .
Continuation all vehicles
– Remove rear left side panel trim ⇒ General body repairs, in‐
terior; Rep. gr. 70 ; Trims, interior; Overview of fitting locations
- interior trims .
Only models with rear loudspeaker system
– Disconnect electrical connectors -3- from loudspeakers.
– Pull out clips -2-.
– Remove screws from spreader rivets -arrows-.
– Pull out spreader rivets -arrows-.
– Remove loudspeaker retaining plate -1-.
n AG. Volkswagen AG do
lkswage es n
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Continuation all vehicles ir se
d b ran
tee
tho
or
– Separate electrical connector -2- on warning buzzer
au 2 for rear ac
ss
parking aid - H31- .
ce
e
nl
pt
du
– Unscrew nuts -arrows- and remove warning buzzer 2 for rear
an
itte
y li
parking aid - H31- -1-.
erm
ab
ility
ot p
Installing
wit
, is n
h re
Install in the reverse order of removal, observing the following:
hole
spec
Specified torques
es, in part or in w
t to the co
rrectness of i
Component Specified torque
l purpos
Nuts on warning buzzer 2 for rear parking aid - H31- 2 Nm
nform
mercia
at
om
ion
c
in t
or
his
ate
do
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cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
211
cted agen
Prote AG.
9. Parking aid
n AG. Volkswagen AG do
wage es n
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , yTransporter
Volks 20 ... ot g
b ua
Electrical system - Edition 04.2019 ir se
d ran
tee
tho
u or
a ac
9.5 Adjusting volume and frequency of ss
ce
le
un
warning buzzer 2 for rear parking aid -
pt
an
d
itte
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H31-
erm
ab
ility
ot p
wit
is n
h re
Note
ole,
spec
urposes, in part or in wh
Adjust volume and frequency of warning buzzer 2 for rear parking
t to the co
aid - H31- ⇒ Vehicle diagnostic tester.
rrectne
9.6 Removing and installing front parking
aid senders
ss o
cial p
f
Removing
inform
mer
atio
Caution
om
n
c
i
or
n thi
♦ The order for removing the senders must be adhered to
te
sd
va
under all circumstances.
i
o
pr
cum
r
fo
♦ The sender may otherwise be damaged. Fractures may
en
ng
t.
yi
occur if too much pressure is applied to the sender, and
Co
Cop py
this may cause the sender to fail.
t. rig
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pyri by
Vo
o
♦ First remove the sender from the retainer and then release
c by lksw
cted agen
and disconnect the sender's connector.
Prote AG.
Outer senders
– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Front bumper; Removing and installing bumper
cover .
– Press both locking lugs in direction of -arrow- while, at the
same time, pressing in sender onto stop from outside.
– Slide locking element in -direction of arrow A-, then push it in
-direction of arrow B- and pull off connector.
Inner senders
The two interior parking aid senders can be removed and installed
without having to remove the front bumper cover.
– Remove noise insulation under engine ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Noise insulation .
212 Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Press both locking lugs in direction of -arrow- while, at the
same time, pressing in sender onto stop from outside.
– Slide locking element in -direction of arrow A-, then push it in
-direction of arrow B- and pull off connector.
Installing
Install in the reverse order of removal, observing the following:
Note
AG. Volkswagen A
♦ When inserting the sender in
olks
wathe
gen sender retainer, make
G do
es n sure
that the isolation ringd (black silicone ring) is seated correctly
V o t gu
by ara
on the sender head.orise nte
e h
ut or
♦ Both locking lugs
ss
a
of sender retainer must audibly engage ac
when installing the sender.
ce
e
nl
pt
du
an
itte
y li
erm
ab
9.7 Removing and installing rear parking aid
ility
ot p
wit
senders
, is n
h re
hole
spec
Removing
es, in part or in w
t to the co
– Remove rear bumper cover -2- ⇒ General body repairs, ex‐
terior; Rep. gr. 63 ; Rear bumper; Removing and installing
rear bumper cover .
rrectness of i
– Release and disconnect connectors -1- on all parking aid
l purpos
senders .
nf
ercia
orm
m
atio
om
n in
or c
thi
te
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9. Parking aid 213
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Electrical system - Edition 04.2019
– Push both locking lugs on bracket -2- outwards -arrows- and
at the same time press parking aid sender -1- from outside
inwards out of bracket.
Installing
Install in the reverse order of removal, observing the following:
Note
♦ When inserting the sender in the sender retainer, make sure
that the isolation ring (black silicone ring) is seated correctly
on the sender head.
♦ Both locking lugs of sender retainer must audibly engage
when installing the sender.
AG. Volkswagen AG d
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214
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Prote AG.
Rep. gr.94 - Lights, bulbs, switches - exterior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
10 Automatic headlight range control
⇒ “10.1 Removing and installing headlight range control unit”,
page 215
10.1 Removing and installing headlight range
control unit
If the control unit is replaced, select the Replace function of the
respective control unit in Guided fault finding ⇒ Vehicle di‐
agnostic tester.
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
AG. Volkswagen
– Remove lower dash panel trim on driver lksw side ⇒ General body es not
agen AG do
repairs, interior; Rep. gr. 68 ; Compartments/covers;
db
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Remov‐ gu
ara
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ise on driver side . nte
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ut or
– Push fastener -3- and pull
ss out headlight range control unit
a ac
-2- from bracket.
ce
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nl
pt
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– Press fastener -1- and swing bar in direction of -arrow-.
– Separate electrical connector -1- on headlight range control
nf
ercia
unit.
rm
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Installing
o
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Installation is carried out in the reverse order. When installing ob‐
te
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serve the following:
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– Check functions of headlight.
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– Check headlight setting and adjust headlight if necessary
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⇒ Maintenance ; Booklet ; Descriptions of work .
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10. Automatic headlight range control 215
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Electrical system - Edition 04.2019
11 Towing bracket
⇒ “11.1 Assembly overview - towing bracket socket”, page 216
⇒ “11.2 Trailer socket U10 ”, page 216
⇒ “11.3 Removing and installing trailer socket U10 ”, page 217
⇒ “11.4 Removing and installing trailer detector control unit J345
”, page 219
11.1 Assembly overview - towing bracket socket
1 - Trailer detector control unit
- J345- AG. Volkswagen AG d
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❑ Removing and installing Volksw not
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⇒ page 219 d b ara
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2 - Retaining frame aut ra
c
ss
❑ For trailer detector con‐
ce
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nl
trol unit - J345-
pt
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3 - Trailer socket - U10-
erm
ab
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❑ Pin assignment
wit
, is n
⇒ page 216
h re
hole
❑ Removing and installing
spec
⇒ page 217
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11.2 Trailer socket - U10-
Properties of pin 9
♦ Pin 9, permanent plus, continuous supply of positive voltage
from battery - A- .
♦ Permanent plus is always directly connected to battery - A- .
♦ Only low current ranges permissible, approx. 7.5 to 10 A
216 Rep. gr.94 - Lights, bulbs, switches - exterior
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Electrical system - Edition 04.2019
Properties of pin 10
♦ Pin 10, charging wire, controlled supply of battery positive
voltage from vehicle to trailer.
♦ Charging current is only supplied with engine running and if
the condition of the onboard power supply is OK.
♦ Higher current ranges permissible, approx. 15 to 20 A (e.g. for
supplying fan heater or charging trailer battery).
Pin assignment of trailer socket - U10-
The exact assignment can be found in the latest current flow di‐
agram ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.
11.3 Removing and installing trailer socket -
U10- en AG. Volkswagen AG
wag does
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♦ If the trailer socket is to be repaired due to e.g. corrosion, ce
e
nl
check in each case whether it is sufficient to renew individual pt
du
an
contacts or seals, or if the entire wiring harness with trailer
itte
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socket must be renewed.
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♦ Because part numbers may vary, check if the installed trailer
wit
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socket is original equipment or a retrofitted accessory before
h re
hole
ordering the replacement part.
spec
es, in part or in w
t to the co
Removing
– Switch off ignition and all electrical consumers, and withdraw
rrectness of i
ignition key.
l purpos
– Remove bolts -arrows-.
– Remove trailer socket - U10- from retaining plate.
nf
ercia
– Pull rubber cover off trailer socket.
rm
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– Disconnect connector -2- for rear fog light cut-out contact
switch - F216- .
11. Towing bracket 217
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Electrical system - Edition 04.2019
– Release retaining clips -arrows- and push multi-pin connector
-1- towards rear out of socket housing -2-.
– Release retaining clips -arrows- and remove retaining cage
-1- from multi-pin connector -3-.
Note
Proceed with care when pulling off retaining cage -1- in order to
prevent the contacts -2- from being disconnected from the wiring
harness.
Installing
Install in the reverse order of removal. When doing this, note the
following: agen
AG. Volkswagen AG d
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♦ The retaining cage -1- can only be pushed onto the multi-pin
ce
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connector -3- and engaged in one specific position.
an
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♦ The guide pins -4- on retaining cage -1- only fit into the multi-
ab
pe
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pin connector -3- in one specific position.
ot
wit
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♦ To insert the guide pins into the multi-pin connector all con‐
h re
hole
tacts -2- must be properly inserted in the retaining cage at the
spec
correct positions.
es, in part or in w
t to the co
– Insert contacts -2- in retaining cage -1- and push retaining
cage into multi-pin connector -3- until it engages audibly.
rrectness of i
– Slide multi-pin connector in correct installation position from
l purpos
behind into socket housing and engage it.
– Fit rubber cover onto socket housing and fit trailer socket to
nform
ercia
retaining plate.
m
– Screw in and tighten three securing bolts.
com
tion in
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Specified torques
te o
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Component Specified torque
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Bolts securing socket to retaining 2 Nm
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Prote AG.
218 Rep. gr.94 - Lights, bulbs, switches - exterior
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Electrical system - Edition 04.2019
11.4 Removing and installing trailer detector
control unit - J345-
Note
The trailer detector control unit - J345- is installed in the seat box
beneath the front passenger seat.
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.agen AG. Volkswagen AG d
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– Move frontd bpassenger
yV seat to the foremost position.
t gu
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– Remove
ut
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a ac
ss
– Press fasteners -2- and swing out control unit -1- from beneath
ce
le
un
bracket.
pt
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– Guide control unit -1- out of bracket.
rm
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– Release and separate electrical connectors -3- on control unit.
ot
wit
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Installing
hole
spec
Installation is carried out in the reverse sequence of removal.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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tion in
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11. Towing bracket 219
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Electrical system - Edition 04.2019
96 – Lights, bulbs, switches - interior
1 Lights
⇒ “1.1 Overview of fitting locations - lights in dash panel”,
page 220
⇒ “1.2 Overview of fitting locations - lights in luggage compart‐
ment”, page 222
⇒ “1.3 Overview of fitting locations - lights in roof trim”,
page 223
⇒ “1.4 Removing and installing glove compartment light W6 ”,
page 223
⇒ “1.5 Replacing bulb for glove compartment light W6 ”,
page 224
⇒ “1.6 Removing and installing front entry light W31 / W32 ”, page
225
⇒ “1.7 Removing and installing bulb for front entry light W31 / W32
”, page 226
⇒ “1.8 Removing and installing rear entry light W33 / W34 ”, page
228
⇒ “1.9 Removing and installing bulb for rear entry light W33 / W34
”, page 228
⇒ “1.10 Removing and installing luggage compartment light W3
”, page 229
⇒ “1.11 Removing and installing bulb for luggage compartment
light W3 ”, page 230
⇒ “1.12 Removing and installing vanity mirror light W20 / W14 ”,
page 230
⇒ “1.13 Removing and installing bulb
wage
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Volkilluminated
swagen AG vanity mirror
does
W20 / W14 ”, page 231 y Volks not
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⇒ “1.14 Removinghoand
ris installing front interior light/reading light”,
nte
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page 231 sa
ut ra
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⇒ “1.15 Removing and installing bulb for front interior light/reading
ce
le
un
pt
light”, page 234
an
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itte
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ab
⇒ “1.16 Removing and installing rear interior light/reading light”,
ility
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page 237
wit
is n
h re
⇒ “1.17 Removing and installing bulb for rear interior light/reading
ole,
light”, page 241
spec
urposes, in part or in wh
t to the co
1.1 Overview of fitting locations - lights in dash panel
rrectness o
cial p
f inform
mer
atio
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Prote AG.
Rep. gr.96 - Lights, bulbs, switches - interior
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Electrical system - Edition 04.2019
1 - Front passenger side airbag
deactivated warning lamp -
K145-
❑ Removing and installing
⇒ page 253
2 - Glove compartment light -
W6-
❑ Removing and installing
⇒ page 223
AG. Volkswagen AG d
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spec
urposes, in part or in wh
t to the co
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1. Lights 221
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Electrical system - Edition 04.2019
AG. Volkswagen AG d
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lksw not
1.2 Overview of fitting locations - lights in luggage compartment
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1 - Luggage compartment light s
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- W3-
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❑ Removing and installing
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⇒ page 229
pe
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Prote AG.
222 Rep. gr.96 - Lights, bulbs, switches - interior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
1.3 Overview of fitting locations - lights in roof trim
1 - Rear interior light/reading
light
❑ Removing and installing
⇒ page 267
❑ Removing and installing
bulb for rear interior
light/reading light
⇒ page 241
2 - Rear interior light
❑ Rear interior light – light
with toggle switch
❑ Removing and installing
⇒ page 267
❑ Removing and installing
bulb for rear interior light
- light with toggle switch
⇒ page 243
❑ Rear interior light – light
with rocker switch
❑ Removing and installing
⇒ page 267
AG. Volkswagen AG d
❑ Removing and installing agen oes
olksw not
bulb for rear interior light d by V gu
ara
- light with toggle switch
orise nte
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⇒ page 242 au
th
ra
ss c
3 - Front courtesy light/reading
ce
le
un
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light
an
d
itte
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❑ Removing and installing
erm
ab
⇒ page 267
ility
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wit
❑ Removing and installing
is n
h re
bulb for front interior
ole,
spec
light/reading light
urposes, in part or in wh
⇒ page 234
t to the co
4 - Front passenger side illu‐
minated vanity mirror
rrectne
❑ Removing and installing ⇒ page 230
5 - Driver side illuminated vanity mirror
ss o
❑ Removing and installing ⇒ page 230
cial p
f inform
mer
atio
om
1.4 Removing and installing glove compart‐
n
c
i
or
n thi
ment light - W6-
te
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Special tools and workshop equipment required
fo
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1. Lights 223
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Electrical system - Edition 04.2019
♦ Removal wedge - 3409-
AG. Volkswagen AG d
agen oes
olksw not
V gu
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Removing
ce
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un
pt
an
d
itte
– Turn light switch to “0” position.
y li
erm
ab
– Switch off ignition and all electrical equipment and then re‐
ility
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move ignition key.
wit
is n
h re
ole,
– Carefully lever out glove compartment light -1- with removal
spec
urposes, in part or in wh
wedge - 3409- or suitable screwdriver.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va
– Release and separate electrical connector -arrow- and re‐
i
o
pr
cum
move glove compartment light -1-.
r
fo
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t.
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Installing
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Install in reverse order of removal. yri
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1.5 Replacing bulb for glove compartment
light - W6-
– Remove glove compartment light ⇒ page 223 .
224 Rep. gr.96 - Lights, bulbs, switches - interior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Release locking lugs -1- and remove heat shield cover -2- from
lens of light.
AG. Volkswagen AG d
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olksw not
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– Carefully lever out bulb from socket. nl
pt
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Glove compartment light bulb: glass base bulb 12V, 5W.
erm
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Installing
wit
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h re
Install in the reverse order of removal. When doing this, note the
hole
spec
following:
es, in part or in w
t to the co
– Check function of glove compartment switch. When the lid is
closed, the glove compartment light should not be on.
rrectness of i
l purpos
nf
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1.6 Removing and installing front entry light
orm
-W31- / -W32-
m
atio
om
n in
c
⇒ “1.6.1 Removing and installing front entry light W31 / W32 ,
or
thi
e
Transporter”, page 225
t
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⇒ “1.6.2 Removing and installing front entry light W31 / W32 ,
o
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f
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Multivan”, page 226
t.
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1.6.1 Removing and installing front entry light
t. rig
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-W31- / -W32- , Transporter
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Prote AG.
Removal and installation of all entry lights are performed in the
same manner and are described only for one light.
Caution
When removing and installing components that are in view
(switches, covers, trims etc.), mask off areas in which tools
(plastic wedge, screwdriver) are used to lever out those com‐
ponents using masking tape.
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
1. Lights 225
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Electrical system - Edition 04.2019
– Apply screwdriver (screwdriver handle must face towards in‐
side of vehicle) and carefully lever out light.
– Release and separate electrical connector.
Installing
Installation is carried out in the reverse sequence of removal.
1.6.2 Removing and installing front entry light
-W31- / -W32- , Multivan
Removal and installation of all entry lights are performed in the
same manner and are described only for one light.
Caution
When removing and installing components that are in view
(switches, covers, trims etc.), mask off areas
n AG. Voinlkswhich
wagen Atools
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wage
(plastic wedge, screwdriver) are yused
Volks to lever out those com‐es not g
ponents using masking tape.ised b ua
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Removing
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an
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– Switch off ignition and all electrical equipment and then re‐
itte
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move ignition key.
ab
ility
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– Fit screwdriver from left side and carefully lever out light.
wit
is n
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ole,
– Release and separate electrical connector.
spec
urposes, in part or in wh
Installing
t to the co
Install in the reverse order of removal. When doing this, note the
following:
rrectne
Fit light first on left side and then engage spring.
ss o
cial p
f inform
mer
atio
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n
c
1.7 Removing and installing bulb for front
i
or
n thi
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a
entry light -W31- / -W32-
iv
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⇒ “1.7.1 Removing and installing bulb for front entry light W31 /
ng
t.
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W32 , Transporter”, page 226 t. Cop py
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⇒ “1.7.2 Removing and installing bulb for front entry light W31 / pyri by
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W32 , Multivan”, page 227
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1.7.1 Removing and installing bulb for front
entry light -W31- / -W32- , Transporter
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove entry light ⇒ page 225 .
226 Rep. gr.96 - Lights, bulbs, switches - interior
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Electrical system - Edition 04.2019
– Release locking lugs -1- and remove cover from bulb carrier
-2-.
– Carefully lever defective bulb out of bulb holder.
– Entry light bulb : glass-base bulb 12V, 5W
Installing
Installation is carried out in the reverse sequence of removal.
AG. Volkswagen AG d
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olksw not
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1.7.2 Removing and installing bulb for front
itte
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entry light -W31- / -W32- , Multivan ab
pe
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ot
wit
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Removing
h re
hole
spec
– Switch off ignition and all electrical equipment and then re‐
es, in part or in w
move ignition key.
t to the co
– Remove entry light ⇒ page 226 .
rrectness of i
– Release locking lugs -1-, and detach bulb carrier -2- from
housing of light.
l purpos
nform
mercia
a
com
tion in
r
te o
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– Carefully pull defective bulb out of bulb holder.
co lksw
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Prote AG.
– Entry light bulb : glass-base bulb 12 V, 1.2 W
Note
To check which bulb is defective, the connector can be fitted to
the lamp carrier.
Installing
Installation is carried out in the reverse sequence of removal.
1. Lights 227
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Electrical system - Edition 04.2019
1.8 Removing and installing rear entry light
-W33- / -W34-
⇒ “1.8.1 Removing and installing rear entry light W33 / W34 ,
Transporter”, page 228
⇒ “1.8.2 Removing and installing rear entry light W33 / W34 ,
Multivan”, page 228
1.8.1 Removing and installing rear entry light
-W33- / -W34- , Transporter
Note
♦ Removal and installation of the rear entry light -W33- / -W34-
in the Transporter is carried out in the same way as for the
front entry light -W31- / -W32- in the Transporter.
♦ Removing and installing front entry light -W31- / -W32- in
Transporter ⇒ page 225 .
1.8.2 Removing and installing rear entry light
-W33- / -W34- , Multivan
Note
♦ Removal and installation of the rear entry light -W33- / -W34-
in the Multivan is carried out in the same way as for the front
entry light -W31- / -W32- in the Multivan.
olkswagen AG
en AG. V
♦ Removing and installing front entry light -W31- / -W32-
olksin Mul‐
wag does
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tivan ⇒ page 226 . db
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1.9 Removing and installing bulb for rear ss c
ce
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entry light -W33- / -W34-
un
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⇒ “1.9.1 Removing and installing bulb for rear entry light W33 /
rm
ab
pe
ility
W34 , Transporter”, page 228
ot
wit
, is n
⇒ “1.9.2 Removing and installing bulb for rear entry light W33 /
h re
hole
W34 , Multivan”, page 229
spec
es, in part or in w
1.9.1 Removing and installing bulb for rear
t to the co
entry light -W33- / -W34- , Transporter
rrectness of i
Note
l purpos
♦ Removal and installation of the bulb for the rear entry light -
nform
ercia
W33- / -W34- in the Transporter is carried out in the same way
as for the front entry light -W31- / -W32- in the Transporter.
m
a
com
tion in
♦ Removing and installing bulb for front entry light -W31- / -W32-
r
te o
thi
in Transporter ⇒ page 226 .
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Prote AG.
228 Rep. gr.96 - Lights, bulbs, switches - interior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
1.9.2 Removing and installing bulb for rear
entry light -W33- / -W34- , Multivan
Note
♦ Removal and installation of the bulb for rear entry light -W33- /
-W34- in the Multivan is carried out in the same way as for the
front entry light -W31- / -W32- in the Multivan.
♦ Removing and installing bulb for front entry light -W31- / -W32-
in Multivan ⇒ page 227 .
1.10 Removing and installing luggage com‐
partment light - W3-
Caution
When removing and installing components that are in view
(switches, covers, trims etc.), mask off areas in which tools
(plastic wedge, screwdriver) are used to lever out those com‐ gen AG. Volkswagen AG
ponents using masking tape. Vol
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ss
Note
ce
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nl
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du
an
itte
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Removal and installation of luggage compartment lights are per‐
erm
ab
formed in the same manner for both lights and are described only
ility
ot p
for one light.
wit
, is n
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hole
spec
Removing
es, in part or in w
t to the co
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Carefully lever out luggage compartment light - W3- using a
rrectness of i
screwdriver.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
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– Release and disconnect connector -arrow-.
op Vo
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Prote AG.
Installing
Installation is carried out in the reverse sequence of removal.
1. Lights 229
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
1.11 Removing and installing bulb for lug‐
gage compartment light - W3-
Removing
– Remove luggage compartment light ⇒ page 229 .
– Press contact plate -1- in -direction of arrow- and remove bulb
-2- from bulb holder.
– Bulb for luggage compartment light : festoon bulb 12V, 10W
n AG. Volkswagen AG do
Installing lkswage es n
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Installation is carriedo
ir seout in the reverse sequence of removal.
ran
tee
th or
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ce
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un
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rm
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ot
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1.12 Removing and installing vanity mirror
hole
spec
light -W20- / -W14-
es, in part or in w
t to the co
Caution
When removing and installing components that are in view rrectness of i
l purpos
(switches, covers, trims etc.), mask off areas in which tools
(plastic wedge, screwdriver) are used to lever out those com‐
nform
ercia
ponents using masking tape.
m
a
com
tion in
The removal and installation procedure for both vanity mirror
r
te o
thi
lights is carried out in the same way and is described just for one
s
iva
do
light.
r
rp
cum
fo
Removing
en
ng
t.
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op py
– Close vanity mirror in sun visor. t. C rig
gh ht
pyri by
– Carefully lever out light using a screwdriver. Fit screwdriver on
co Vo
by lksw
cted
recess -arrow-.
agen
Prote AG.
230 Rep. gr.96 - Lights, bulbs, switches - interior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan
AG. Vol2016
kswage➤
n A,GTransporter 20 ...
agen does
olksw Electrical system - Editionnot 04.2019
V y gu
db ara
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– Release and disconnect connector -arrows-. tho
r eo
au ra
c
Installing ss
ce
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nl
pt
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Installation is carried out in the reverse sequence of removal.
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
1.13 Removing and installing bulb for illumi‐
l purpos
nated vanity mirror -W20- / -W14-
nform
ercia
Removing
m
at
om
– Remove illuminated vanity mirror light ⇒ page 230 .
ion
c
in t
or
– Press contact plate -1- in -direction of arrow- and remove bulb
his
ate
-2- from bulb holder.
do
priv
cum
or
– Bulb for illuminated vanity mirror : festoon bulb 12V, 5W
f
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ng
t.
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op
Installing C py
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Installation is carried out in the reverse sequence of removal. op Vo
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Prote AG.
1.14 Removing and installing front interior
light/reading light
⇒ “1.14.1 Removing and installing front interior light, Multivan”,
page 231
⇒ “1.14.2 Removing and installing front interior light, Transporter”,
page 232
⇒ “1.14.3 Removing and installing front reading light”, page 233
1.14.1 Removing and installing front interior
light, Multivan
Caution
When removing and installing components that are in view
(switches, covers, trims etc.), mask off areas in which tools
(plastic wedge, screwdriver) are used to lever out those com‐
ponents using masking tape.
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
1. Lights 231
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Carefully lever out lens of front interior light - W1- -arrow-.
– Carefully lever interior and reading light out of mounting frame
using a -screwdriver-.
AG. Volkswagen AG d
agen oes
olksw not
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ed
ris nte
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aut ra
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ce
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nl
pt
du
an
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erm
ab
ility
ot p
wit
, is n
h re
– Release and disconnect connector -arrow-.
hole
spec
Installing
es, in part or in w
t to the co
Installation is carried out in the reverse sequence of removal.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
1.14.2 Removing and installing front interior
at
do
priv
light, Transporter
um
for
en
ng
t.
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Cop py
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Caution rig ht
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co Vo
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When removing and installing components that are in view Prote AG.
(switches, covers, trims etc.), mask off areas in which tools
(plastic wedge, screwdriver) are used to lever out those com‐
ponents using masking tape.
Removing
– Switch off ignition and all electrical consumers, and withdraw
ignition key.
232 Rep. gr.96 - Lights, bulbs, switches - interior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
Version 1:
– Carefully lever interior light out of mounting frame -arrow-.
olkswagen AG
en AG. V
– Release and separate electrical
olksconnector.
wag does
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Version 2: ir se nte
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– Unclip lens. ss
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c
ce
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un
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an
d
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Unscrew screws -arrows- in interior light.
– Detach side fasteners and carefully remove interior light from
mounting frame.
rrectne
– Release and separate electrical connector.
ss o
Installing
cial p
f inform
Installation is carried out in the reverse sequence of removal.
mer
atio
om
n
c
i
or
n thi
te
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pr
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t.
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1.14.3 Removing and installing front reading
Co
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light
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
When removing and installing components that are in view
(switches, covers, trims etc.), mask off areas in which tools
(plastic wedge, screwdriver) are used to lever out those com‐
ponents using masking tape.
Special tools and workshop equipment required
♦ Removal wedge - 3409-
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
1. Lights 233
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Carefully lever lens of front passenger reading light - W13- and
driver side reading light - W19- out of mounting frame
-arrow-.
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
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au ra
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ce
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nl
pt
du
an
itte
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– Carefully lever reading light out of mounting frame using a
erm
ab
-screwdriver-.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
– Release and disconnect connector -arrow-.
m
atio
om
n in
c
Installing
or
thi
te
sd
a
Installation is carried out in the reverse sequence of removal.
iv
o
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m
f
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ng
t.
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Cop py
t. rig
gh ht
pyri by
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Prote AG.
1.15 Removing and installing bulb for front
interior light/reading light
⇒ “1.15.1 Removing and installing bulb for front interior light, Mul‐
tivan”, page 234
⇒ “1.15.2 Removing and installing bulb for front interior light,
Transporter”, page 235
⇒ “1.15.3 Removing and installing bulb for front reading light”,
page 236
1.15.1 Removing and installing bulb for front
interior light, Multivan
Caution
When removing and installing components that are in view
(switches, covers, trims etc.), mask off areas in which tools
(plastic wedge, screwdriver) are used to lever out those com‐
ponents using masking tape.
234 Rep. gr.96 - Lights, bulbs, switches - interior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
Removing
– Carefully lever out lens of front interior light - W1- -arrow-.
– Press contact plate -1- in -direction of arrow- and remove bulb
-2- from bulb holder.
– Bulb for front interior light : festoon bulb 12V, 10W
Installing agen
AG. Volkswagen AG d
oes
olksw not
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Installation is carried out in the reverse sequence d b of removal.
y ara
rise nte
tho eo
au ra
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ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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1.15.2 Removing and installing bulb for front
hole
spec
interior light, Transporter
es, in part or in w
t to the co
Caution
rrectness of i
When removing and installing components that are in view
l purpos
(switches, covers, trims etc.), mask off areas in which tools
(plastic wedge, screwdriver) are used to lever out those com‐
ponents using masking tape.
nform
mercia
a
com
tio
Removing
n in
r
te o
thi
– Pull lens -arrow- off reflector.
s
iva
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cum
fo
en
ng
t.
Note
yi Co
Cop py
t. rig
gh ht
yri
Depending on version, the interior light may look different from p by
co Vo
interior light in illustration.
by lksw
cted agen
Prote AG.
1. Lights 235
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Press contact plate -1- in -direction of arrow- and remove bulb
-2- from bulb holder.
– Bulb for front interior light : festoon bulb 12V, 10W
Installing
Installation is carried out in the reverse sequence of removal.
1.15.3 Removing and installing bulb for front
reading light
Note
Removal and installation of the bulbs are carried out in the same
way for both reading lights and are described only for one light.
Removing AG. Volkswagen AG d
agen oes
ksw
– Switch off ignition and all electrical equipment and then re‐ by
Vol not
gu
ara
move ignition key. rised
nte
ho eo
ut
– Remove front reading light ⇒ page 231 . ss a ra
c
ce
e
– Turn bulb holder in direction of -arrow- and pull out.
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Carefully pull bulb straight out of bulb holder.
nf
ercia
– Bulb for front reading light : glass-base bulb 12V, 5W orm
m
atio
om
Installing
n in
or c
thi
e
Installation is carried out in the reverse sequence of removal.
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
236 Rep. gr.96 - Lights, bulbs, switches - interior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
1.16 Removing and installing rear interior
light/reading light
⇒ “1.16.1 Removing and installing reargeinterior
n AG. Voland
kswareading
gen AG light,
does
Multivan”, page 237 Volkswa not
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db ara
⇒ “1.16.2 Removing and installing
or
ise centre interior light and front nte
interior light in high roof”,
authpage 238 eo
ra
ss c
⇒ “1.16.3 Removing and installing rear interior light with rotary
ce
le
un
pt
pushbutton”, page 239
an
d
itte
y li
⇒ “1.16.4 Removing and installing rear interior light with rocker
erm
ab
ility
switch”, page 239
ot p
wit
is n
⇒ “1.16.5 Removing and installing rear interior light with toggle
h re
ole,
switch”, page 240
spec
urposes, in part or in wh
1.16.1 Removing and installing rear interior
t to the co
and reading light, Multivan
rrectne
Note
ss o
cial p
f
♦ Depending on the equipment level, the interior lights and read‐
inform
ing lamps of the 1st row of seats include the left interior light -
mer
W16- , the centre left reading lamp - W39- , the right interior
atio
m
light - W17- and the centre right reading lamp - W40- .
o
n
c
i
or
n thi
♦ Depending on the equipment level, the interior lights and read‐
te
sd
a
ing lamps of the 2nd row of seats include the rear left interior
iv
o
pr
c
light - W47- , the rear left reading lamp - W11- , the rear right um
r
fo
en
ng
interior light - W48- and the rear right reading lamp - W12- .
t.
yi Co
op py
♦ Removal and installation of interior lights in 1st and 2nd row
t. C rig
gh ht
yri
of seats are performed in the same manner and are described p by
co Vo
only for one light.
by lksw
cted agen
Prote AG.
Caution
When removing and installing components that are in view
(switches, covers, trims etc.), mask off areas in which tools
(plastic wedge, screwdriver) are used to lever out those com‐
ponents using masking tape.
Special tools and workshop equipment required
♦ Removal wedge - 3409-
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
1. Lights 237
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ar
California 2016 ➤ , Caravelle 2016 oris ➤ , Multivan 2016 ➤ , Transporter 20 a...
e nte
h eo
Electrical system - Edition 04.2019
aut ra
c
ss
ce
le
– Carefully lever out light using a removal wedge - 3409- .
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f
– Release and disconnect connector -arrows-.
inform
mer
Installing
atio
om
n
Installation is carried out in the reverse sequence of removal.
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
1.16.2 Removing and installing centre interior
light and front interior light in high roof
Note
♦ Depending on level of equipment, the centre interior light -
W7- , the front interior light in high roof - W28- and the rear
interior light - W43- are installed in Multivan with long wheel
base, Transporter with flat roof, medium-high roof and high
roof or shuttle.
♦ The removal and installation procedure for both interior lights
is carried out in the same way and is described only for one
light.
Caution
When removing and installing components that are in view
(switches, covers, trims etc.), mask off areas in which tools
(plastic wedge, screwdriver) are used to lever out those com‐
ponents using masking tape.
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
238 Rep. gr.96 - Lights, bulbs, switches - interior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Carefully lever out light using a screwdriver.
– Release all four locking lugs -arrows- and carefully pull out
light downwards.
– Release and separate electrical connector.
Installing
Installation is carried out in the reverse sequence of removal.
1.16.3 Removing and installing rear interior
light with rotary pushbutton
Removal and installation of the rear interior light with rotary push‐
button are carried out in the same way as the removal and
installation of the centre interior light and the front interior light in
high roof ⇒ page 238 . agen
AG. Volkswagen AG d
o w es n
olks ot g
1.16.4 Removing and installing rear interior ris
ed
byV ua
ran
tee
light with rocker switch au
tho or
ac
ss
ce
le
un
pt
an
d
Note
itte
y li
rm
ab
pe
ility
♦ Depending on the equipment level, the centre interior light -
ot
wit
W7- , the front interior light in high roof - W28- and the rear
, is n
h re
interior light - W43- are installed in Multivan with long wheel
hole
spec
base, Transporter with flat roof, medium-high roof and high
es, in part or in w
roof or shuttle.
t to the co
♦ The removal and installation procedure for both interior lights
is carried out in the same way and is described only for one
rrectness of i
light.
l purpos
Caution
nform
ercia
When removing and installing components that are in view
m
a
com
(switches, covers, trims etc.), mask off areas in which tools
ion in
(plastic wedge, screwdriver) are used to lever out those com‐
r
te o
thi
ponents using masking tape.
s
iva
do
r
rp
cum
fo
en
ng
Removing
t.
yi Co
Cop py
. rig
– Switch off ignition and all electrical equipment and then re‐
t
gh ht
yri by
move ignition key. cop Vo
by lksw
cted agen
Prote AG.
1. Lights 239
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Carefully lever out light in -direction of arrow- using a screw‐
driver.
– Release and disconnect connector -arrows-.
Installing
Installation is carried out in the reverse sequence of removal.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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un
pt
an
d
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rm
ab
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ility
ot
wit
, is n
1.16.5 Removing and installing rear interior
h re
hole
light with toggle switch
spec
es, in part or in w
t to the co
Caution
rrectness of i
When removing and installing components that are in view
(switches, covers, trims etc.), mask off areas in which tools
l purpos
(plastic wedge, screwdriver) are used to lever out those com‐
ponents using masking tape.
nform
mercia
a
com
tion in
r
Note
te o
thi
s
iva
do
r
rp
The procedure for removal and installation of the interior lights
cum
fo
above the right-hand sliding door is performed in the same way
en
ng
t.
yi
and is only described for one light.
Co
Cop py
t. rig
gh ht
pyri by
Special tools and workshop equipment required
co Vo
by lksw
cted agen
Prote AG.
♦ Removal wedge - 3409-
240 Rep. gr.96 - Lights, bulbs, switches - interior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Using removal wedge - 3409- , lever light out of mountings on
left and right -arrow-. n AG. Volkswagen A G do
wage es n
Volks ot g
by ua
ed ran
oris tee
th or
au ac
ss
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Release -arrows- and disconnect -A- connector.
rrectne
Note
s
The lighting elements for the interior light above the right-hand
s o
sliding door have light-emitting diodes and cannot be repaired. If
cial p
f in
repair is required, the entire light must be replaced.
form
mer
atio
m
Installing
o
n
c
i
or
n thi
Installation is carried out in the reverse sequence of removal.
te
sd
iva
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pr
cum
r
fo
en
ng
t.
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1.17 Removing and installing bulb for rear in‐
Co
Cop py
ht. rig
terior light/reading light
rig ht
py by
co Vo
by lksw
cted agen
⇒ “1.17.1 Removing and installing centre interior light, interior light Prote AG.
in high roof and rear interior light (rotary pushbutton)”,
page 241
⇒ “1.17.2 Removing and installing bulb for rear interior light with
rocker switch”, page 242
⇒ “1.17.3 Removing and installing bulb for rear interior light with
toggle switch”, page 243
⇒ “1.17.4 Removing and installing bulb for rear reading light”,
page 243
1.17.1 Removing and installing centre interior
light, interior light in high roof and rear
interior light (rotary pushbutton)
Caution
When removing and installing components that are in view
(switches, covers, trims etc.), mask off areas in which tools
(plastic wedge, screwdriver) are used to lever out those com‐
ponents using masking tape.
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
1. Lights 241
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Carefully lever out respective lens using a screwdriver.
– Push bulb in -direction of arrow- and remove it from bulb hold‐
er.
– Bulb for interior light or bulb for rear reading light : festoon bulb
12V, 10W
Installing
Installation is carried out in the reverse sequence of removal.
1.17.2 Removing and installing bulb for rear in‐
terior light with rocker Aswitch
G. Volkswagen A
agen G do
es n
ksw
y Vol ot g
ua
b
Caution ris
ed ran
tee
tho
or
au ac
When removing andss installing components that are in view
(switches, covers, trims etc.), mask off areas in which tools
ce
le
un
pt
(plastic wedge, screwdriver) are used to lever out those com‐
an
d
itte
y li
ponents using masking tape.
erm
ab
ility
ot p
wit
is n
Removing
h re
ole,
spec
– Switch off ignition and all electrical equipment and then re‐
urposes, in part or in wh
move ignition key.
t to the co
– Remove rear interior light ⇒ page 238 .
rrectne
– Release locking lugs -arrows- and remove lens from bulb car‐
rier.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
242 Rep. gr.96 - Lights, bulbs, switches - interior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Push bulb in -direction of arrow- and remove it from bulb hold‐
er.
– Bulb for rear interior light : 12V, 10W
Installing
Installation is carried out in the reverse sequence of removal.
1.17.3 Removing and installing bulb for rear in‐
terior light with toggle switch
The lighting elements for the rear interior light bulb have light-
emitting diodes and cannot be repaired. In the event of repair, the
entire light must be replaced ⇒ page 237 .
1.17.4 Removing and installing bulb for rear
reading light
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key. n AG. Volkswagen AG do
swage es n
– Remove rear interior and reading light ⇒ page 237 .by Vo lk ot g
ua
d ran
ir se
– Turn bulb holder in -direction of arrow- and pullth it out.
o tee
or
au ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Pull bulb straight out of bulb holder.
l purpos
– Bulb for rear reading light : glass-base bulb 12V, 5W
nf
ercia
Installing
orm
m
atio
Installation is carried out in the reverse sequence of removal.
om
n in
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thi
te
sd
iva
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t.
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Lights 243
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Electrical system - Edition 04.2019
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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nl
pt
du
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itte
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ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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orm
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
244 Rep. gr.96 - Lights, bulbs, switches - interior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
2 Controls
AG. Volkswagen AG d
⇒ “2.1 Overview of fitting locations - controls in dash panel”, page wage
n oes
olks not
246 db
y V gu
ara
e nte
ris
⇒ “2.2 Overview of fitting locations - controls in frontudoors”,
tho page eo
ra
248 ss a c
ce
le
⇒ “2.3 Overview of fitting locations - controls in luggage compart‐
un
pt
an
d
ment”, page 249
itte
y li
erm
ab
⇒ “2.4 Overview of fitting locations - controls in roof trim”,
ility
ot p
page 250
wit
is n
h re
ole,
⇒ “2.5 Removing and installing rotary light switch EX1 ”,
spec
page 250
urposes, in part or in wh
t to the co
⇒ “2.6 Removing and installing regulator for switch and instrument
illumination E20 ”, page 251
rrectne
⇒ “2.7 Removing and installing headlight range control regulator
E102 ”, page 252
s
⇒ “2.8 Removing and installing Start/Stop operation button E693
s o
cial p
”, page 252
f inform
mer
⇒ “2.9 Removing and installing TCS and ESP button E256 ”, page
atio
252
om
n
c
i
or
n
⇒ “2.10 Removing and installing parking aid button E266 ”, page
thi
e
253
t
sd
iva
o
pr
cum
⇒ “2.11 Removing and installing front passenger side airbag de‐
r
fo
en
ng
activated warning lamp K145 ”, page 253
t.
yi Co
Cop py
⇒ “2.12 Removing and installing heated rear window switch E15 ht. rig
rig ht
”, page 253
py by
co Vo
by lksw
cted agen
⇒ “2.13 Removing and installing tyre pressure monitor display
Prote AG.
button E492 ”, page 253
⇒ “2.14 Removing and installing heated windscreen button E627
”, page 254
⇒ “2.15 Removing and installing rear differential lock switch E121
”, page 254
⇒ “2.16 Removing and installing hill descent control button E618
”, page 255
⇒ “2.17 Removing and installing sliding door button E442 ”, page
255
⇒ “2.18 Removing and installing button to deactivate sliding door
E443 ”, page 255
⇒ “2.19 Removing and installing interior light switch (taxi) E115 ”,
page 255
⇒ “2.20 Removing and installing taxi sign switch E138 ”,
page 255
⇒ “2.21 Removing and installing buttons in centre of dash panel”,
page 256
⇒ “2.22 Removing and installing hazard warning light switch EX3
”, page 257
⇒ “2.23 Removing and installing buttons for seat heating E653 /
E654 ”, page 257
⇒ “2.24 Removing and installing glove compartment light switch
E26 ”, page 257
⇒ “2.25 Removing and installing mirror adjustment switch E43 /
E168 ”, page 258
2. Controls 245
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Electrical system - Edition 04.2019
⇒ “2.26 Removing and installing operating unit for window regu‐
lator in driver door E512 ”, page 259
⇒ “2.27 Removing and installing window regulator switch in front
AG. Volkswagen AG d
passenger door E107 ”, page l260
ksw
agen oes
n o ot g
yV u
⇒ “2.28 Removing and rinstalling
ise
db driver side interior locking button
ara
nte
for central locking system
ut
ho E308 ”, page 260 eo
r
sa ac
⇒ “2.30 Removings and installing door contact switch F2 / F3 ”,
ce
le
page 262
un
pt
an
d
itte
y li
⇒ “2.31 Removing and installing rear door contact switches F10 /
rm
ab
F11 ”, page 262
pe
ility
ot
wit
, is n
⇒ “2.32 Removing and installing release button for rear lid lock
h re
cylinder F248 ”, page 264
hole
spec
es, in part or in w
⇒ “2.35 Removing and installing rear lid contact switch”,
t to the co
page 265
⇒ “2.36 Removing and installing vanity mirror contact switch
rrectness of i
F147 / F148 ”, page 265
l purpos
⇒ “2.37 Removing and installing sliding sunroof adjustment reg‐
ulator E139 ”, page 265
nform
ercia
⇒ “2.38 Removing and installing front interior light/reading light”,
page 267
m
a
com
tio
⇒ “2.39 Removing and installing rear interior light/reading light”,
n in
r
page 267
te o
thi
s
iva
do
⇒ “2.40 Removing and installing front reading light button E633 /
r
rp
cum
E634 and button for central deactivation of interior light”,
fo
en
g
page 267
n
t.
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Cop py
⇒ “2.41 Controls in interior, Business”, page 269
t. rig
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pyri by
Vo
co
2.1 Overview of fitting locations - controls in dash panel
by lksw
cted agen
Prote AG.
Note
The illustration shows fitting locations for left-hand drive vehicles. Fitting locations for right-hand drive vehicles
are similar.
246 Rep. gr.96 - Lights, bulbs, switches - interior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
1 - Rotary light switch - EX1-
❑ Removing and installing
⇒ page 250
2 - Headlight range control reg‐ AG. Volkswagen AG d
agen
ulator - E102- olksw
oes
not
byV gu
ara
❑ Removing and installing
rised
nte
⇒ page 252 ut
ho eo
r a ac
ss
3 - Key operated switch to de‐
ce
e
nl
activate front passenger side
pt
du
an
airbag - E224-
itte
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erm
ab
❑ Assembly overview ⇒
ility
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General body repairs,
wit
, is n
interior; Rep. gr. 69 ;
h re
Airbag (front passenger
hole
spec
side); Assembly over‐
es, in part or in w
view - airbag (front pas‐
t to the co
senger side)
4 - Button for left seat heating
rrectness of i
- E653-
l purpos
❑ Integrated in operating
and display unit:
nf
ercia
♦ Heater control unit - J65-
or
OR
m
m
atio
m
♦ air conditioning system
o
n in
or c
control unit - J301- OR
thi
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sd
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♦ Climatronic control unit -
o
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J255-
o
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t.
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❑ Cannot be renewed
Co
op py
separately if defective.
. C rig
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rig by
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❑ Removing and installing co Vo
by lksw
-J65- / -J301- / -J255- ⇒
cted agen
Prote AG.
Heating, air condition‐
ing; Rep. gr. 87 ; Over‐
view of fitting locations -
operating and display
unit .
5 - Button for right seat heating - E654-
❑ Integrated in operating and display unit:
♦ Heater control unit - J65- OR
♦ air conditioning system control unit - J301- OR
♦ Climatronic control unit - J255-
❑ Cannot be renewed separately if defective.
❑ Removing and installing -J65- / -J301- / -J255- ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of
fitting locations - operating and display unit .
6 - Tyre pressure monitor display button - E492-
❑ Only in vehicles with »Low Line« dash panel insert
❑ Removing and installing ⇒ page 253
7 - Glove compartment light switch - E26-
❑ Removing and installing ⇒ page 257
8 - Buttons in centre of dash panel on right
♦ TCS and ESP button - E256-
♦ Rear differential lock switch - E121-
♦ Hill descent control button - E618-
2. Controls 247
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Electrical system - Edition 04.2019
♦ Left sliding door button - E442-
♦ Deactivation of sliding door button - E443-
♦ Right sliding door button - E442-
♦ Interior light switch (taxi) - E115-
♦ Taxi sign switch - E138- AG. Volkswagen AG d
agen oes
olksw not
❑ Removing and installing ⇒ page 256 ed by
V gu
ara
ris nte
9 - Buttons in centre of dash panel on left
aut
ho eo
ra
s c
❑ Start/stop operation switch - E693-
s
ce
e
nl
pt
❑ Front passenger side airbag deactivated warning lamp - K145-
du
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itte
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❑ Hazard warning light switch - EX3-
erm
ab
ility
❑ Parking aid button - E266-
ot p
wit
, is n
❑ Heated rear window switch - E15-
h re
hole
❑ Heated windscreen button - E627-
spec
es, in part or in w
❑ Removing and installing ⇒ page 256
t to the co
rrectness of i
2.2 Overview of fitting locations - controls in front doors
l purpos
1 - Rear lid remote release but‐
nf
ercia
ton - E233-
orm
❑ Removing and installing
m
atio
m
⇒ page 262
o
n in
or c
thi
2 - Operating unit for window
te
sd
a
regulator in driver door - E512-
iv
o
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rp
cu
❑ with:
o
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ng
t.
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♦ Front driver side window Cop py
t. rig
regulator button - E710- opyri
gh by
Vo
ht
by c lksw
♦ Front passenger side win‐ Prote
cted agen
dow regulator button -
AG.
E716-
❑ Removing and installing
⇒ page 259
3 - Mirror adjustment switch -
E43-
❑ Removing and installing
⇒ page 258
4 - Driver side interior locking
button for central locking sys‐
tem - E308-
❑ Depending on equip‐
ment
❑ Removing and installing
⇒ page 260
5 - Front passenger side win‐
dow regulator button - E716-
❑ Removing and installing
⇒ page 260
248 Rep. gr.96 - Lights, bulbs, switches - interior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
2.3 Overview of fitting locations - controls in luggage compartment
n AG. Volkswagen AG do
1 - Rear lid warning ksw buzzer -
age es n
H32- y Vol ot g
ua
b
ed ran
oris
❑ Removing and installing tee
th or
s au⇒ page 264 ac
s
ce
e
2 - Release button for rear lid
nl
pt
du
an
lock cylinder - F248-
itte
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erm
ab
❑ Removing and installing
ility
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⇒ page 264
wit
, is n
h re
3 - Rear door contact switch -
hole
F10- / -F11-
spec
es, in part or in w
❑ Removing and installing
t to the co
⇒ page 262
4 - Door lock
rrectness of i
❑ Removing and installing
⇒ General body repairs,
l purpos
exterior; Rep. gr. 58 ;
Door components; Re‐
nf
ercia
moving and installing
or
door lock .
m
m
atio
om
5 - Rear lid contact switch
n in
or c
thi
❑ with:
te
sd
iva
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♦ Rear lid contact switch -
o
m
f
F111-
en
ng
t.
yi Co
op
♦ Luggage compartment light
C py
t. rig
gh
switch - F5-
ht
pyri by
Vo
co lksw
by
❑ Removing and installing Prote
cted AG.
agen
⇒ page 265
6 - Button for closing rear lid -
E574-
❑ Removing and installing
⇒ page 264
2. Controls 249
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Electrical system - Edition 04.2019
2.4 Overview of fitting locations
agen
AG. V-olcontrols
kswagen AG in roof trim
do
ksw es n
Vol ot g
d by ua
ran
e
ris tee
Note tho or
au ac
ss
The illustration shows fitting locations for left-hand drive vehicles. Fitting locations for right-hand drive vehicles
ce
le
un
pt
are similar.
an
d
itte
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ab
pe
ility
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wit
1 - Front reading light button -
, is n
h re
E633- / -E634- and button for
hole
spec
central deactivation of interior
es, in part or in w
light
t to the co
❑ with:
♦ Front interior light button -
rrectness of i
W1-
l purpos
♦ Front left reading light but‐
ton - E633-
nform
ercia
♦ Front right reading light but‐
ton - E634-
m
a
com
tio
❑ Removing and installing
n in
r
⇒ page 267
te o
thi
s
iva
do
2 - Sliding sunroof adjustment
r
rp
cum
regulator - E139-
fo
en
ng
t.
yi
❑ Removing and installing
Co
op py
⇒ page 265
t. C rig
gh ht
pyri by
Vo
3 - Front passenger vanity mir‐
o
by c lksw
cted agen
ror contact switch - F148- Prote AG.
❑ Removing and installing
⇒ page 265
4 - Driver vanity mirror contact
switch - F147-
❑ Removing and installing
⇒ page 265
2.5 Removing and installing rotary light
switch - EX1-
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Turn knob of rotary light switch - EX1- to position 0 .
250 Rep. gr.96 - Lights, bulbs, switches - interior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
olkswagen AG
en AG. V
– Press in knob of rotary olight
ksw switch - EX1- -arrow eA-
ag do s and turn
not
V l
clockwise onto stop
ed
b-arrow B-.
y gu
ara
ris nte
– Hold knob in athis
ut position and pull rotary knob to remove rotaryor a
ho e
light switch s- EX1- from dash panel -arrow C-.
s c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Release and separate electrical connector -arrow- on head‐
rrectness of i
light - EX1- -1-.
Installing
l purpos
– Connect connector and engage it.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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t.
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Cop py
t. rig
– Press in knob of rotary light switch - EX1- -arrow A- and turn
gh ht
pyri by
clockwise onto stop -arrow B-.
o Vo
by c lksw
cted agen
Prote AG.
– Hold grip in this position, and insert rotary light switch - EX1-
into dash panel -arrow C-.
– Turn grip to position 0 , release and engage rotary light switch
- EX1- in installation position.
2.6 Removing and installing regulator for
switch and instrument illumination -
E20-
Note
♦ The switch and instrument illumination regulator - E20- is part
of the headlight range control regulator - E102- .
♦ Removing and installing headlight range control regulator -
E102- ⇒ page 252 .
2. Controls 251
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Electrical system - Edition 04.2019
2.7 Removing and installing headlight range
control regulator - E102-
Note
The switch and instrument illumination regulator - E20- is part of
the headlight range control regulator - E102- .
Removing
– Switch off ignition and all electrical consumers, and withdraw
ignition key.
– Remove dash panel trim on driver side ⇒ General body re‐
pairs, interior; Rep. gr. 70 ; Dash panel; Assembly overview
– dash panel .
– Press side locking lugs -arrows- together and pull out head‐
light range control regulator - E102- -1- backwards out of trim
-2-.
– Release and disconnect electrical connector -3-.
Installing
Install in the reverse order of removal, observing the following:
– Engage headlight range control regulator - E102- securely in
trim.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut
2.8 Removing and installing Start/Stop op‐ a ra
ss c
ce
le
eration button - E693-
un
pt
an
d
itte
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rm
ab
pe
ility
Note
ot
wit
, is n
h re
♦ The Start/Stop operation button - E693- is installed in the
hole
spec
switch unit in the centre of the dash panel.
es, in part or in w
t to the co
♦ It is removed and installed in the same way as all other buttons
in the centre of the dash panel ⇒ page 256 .
rrectness of i
2.9 Removing and installing TCS and ESP
l purpos
button - E256-
nform
mercia
Note
a
com
tion in
r
♦ The TCS and ESP button - E256- is fitted on all 4Motion ve‐
te o
thi
hicles and vehicles with rear-wheel drive.
s
iva
do
r
rp
cum
♦ As of September 2018, the TCS and ESP button - E256- can
fo
en
ng
also be fitted on vehicles with front-wheel drive, depending on
t.
yi Co
op
the equipment level. C py
ht. rig
rig ht
py by
♦ The button for TCS and electronic stabilisation program - co Vo
by lksw
E256- is installed in the switch unit in the centre of the dash cted agen
Prote AG.
panel.
♦ It is removed and installed in the same way as all other buttons
in the centre of the dash panel ⇒ page 256 .
252 Rep. gr.96 - Lights, bulbs, switches - interior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
2.10 Removing and installing parking aid but‐
ton - E266-
Note
♦ The parking aid button - E266- is installed in the switch unit in
the centre of the dash panel.
♦ It is removed and installed in the same way as all other buttons
in the centre of the dash panel ⇒ page 256 .
2.11 Removing and installing front passenger
side airbag deactivated warning lamp -
K145-
Note
. Volkswagen AG
gen AG
♦ The front passenger
ksw side airbag deactivated
oes warning lamp -
a d
not
Vol
K145- is located
ed
by in the switch unit in the centre gof
uathe dash
ran
panel. thoris tee
or
au a
♦ It is removed
ss and installed in the same way as all other buttons
c
in the centre of the dash panel ⇒ page 256 .
ce
e
nl
pt
du
an
itte
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erm
2.12 Removing and installing heated rear
ab
ility
ot p
window switch - E15-
wit
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
♦ The heated rear window switch - E15- is installed in the switch
unit in the centre of the dash panel.
rrectness of i
♦ It is removed and installed in the same way as all other buttons
l purpos
in the centre of the dash panel ⇒ page 256 .
nf
ercia
2.13 Removing and installing tyre pressure
orm
m
atio
monitor display button - E492-
om
n in
or c
thi
te
sd
iva
Note
o
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rp
cu
o
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f
en
ng
t.
♦ The Tyre Pressure Loss Indicator button - E492- is used for
yi Co
op
storing the current tyre pressures to enable monitoring by the
C py
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Tyre Pressure Monitoring System.
ht
pyri by
Vo
co lksw
by
cted
♦ The Tyre Pressure Loss Indicator button - E492- is installed
agen
Prote AG.
only in vehicles equipped with a tyre monitoring system in
conjunction with a »Low Line« dash panel insert.
♦ In vehicles equipped with a tyre monitoring system in con‐
junction with a »High Line« dash panel insert, the current tyre
pressures are stored via a menu option in the dash panel in‐
sert.
♦ The Tyre Pressure Loss Indicator button - E492- is then loca‐
ted in the glove compartment.
Special tools and workshop equipment required
2. Controls 253
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Electrical system - Edition 04.2019
♦ Removal wedge - 3409-
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove glove compartment far enough to gain access to rear
of Tyre Pressure Loss Indicator button - E492- ⇒ General
body repairs, interior; Rep. gr. 68 ; Compartments/covers;
Removing and installing glove compartment .
– Press fasteners on Tyre Pressure Loss Indicator button -
E492- -1-, and push button from rear out of mounting hole in
glove compartment.
– Release and disconnect connector -arrow-.
Installing
Install in reverse order of removal.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
2.14 Removing and installing heated wind‐ ise nte
or eo
h
ut ra
screen button - E627- ss a c
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
♦ The heated windscreen button - E627- is installed in the switch
, is n
h re
unit in the centre of the dash panel.
hole
spec
♦ It is removed and installed in the same way as all other buttons
es, in part or in w
t to the co
in the centre of the dash panel ⇒ page 256 .
2.15 Removing and installing rear differential
rrectness of i
lock switch - E121-
l purpos
nform
ercia
Note
m
at
om
♦ The rear differential lock switch - E121- is installed in the
ion
c
switch unit in the centre of the dash panel.
in t
or
his
ate
♦ It is removed and installed in the same way as all other buttons
do
priv
in the centre of the dash panel ⇒ page 256 .
um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
254 Rep. gr.96 - Lights, bulbs, switches - interior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
AG. Volkswagen
Electrical system - Edition 04.2019
n AG do
wage es n
olks ot g
2.16 Removing and installing hill descent
V
by ua
ed ran
ris tee
control button - E618- tho
or
au ac
ss
ce
le
un
pt
an
d
Note
itte
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erm
ab
ility
♦ The hill descent control button - E618- is installed in the switch
ot p
wit
unit in the centre of the dash panel.
is n
h re
ole,
♦ It is removed and installed in the same way as all other buttons
spec
urposes, in part or in wh
in the centre of the dash panel ⇒ page 256 .
t to the co
2.17 Removing and installing sliding door
rrectne
button - E442-
ss o
Note
cial p
f inform
mer
♦ The left sliding door button - E442- or right sliding door button
atio
m
- E442- is installed in the switch unit in the centre of the dash
o
n
c
panel.
i
or
n thi
te
sd
a
♦ It is removed and installed in the same way as all other buttons
iv
o
pr
c
in the centre of the dash panel ⇒ page 256 .
um
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fo
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t.
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2.18 Removing and installing button to deac‐
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tivate sliding door - E443- cop Vo
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Prote AG.
Note
♦ The button to deactivate sliding door - E443- is installed in the
switch unit in the centre of the dash panel.
♦ It is removed and installed in the same way as all other buttons
in the centre of the dash panel ⇒ page 256 .
2.19 Removing and installing interior light
switch (taxi) - E115-
Note
♦ The interior light switch (taxi) - E115- is installed in the switch
unit in the centre of the dash panel.
♦ It is removed and installed in the same way as all other buttons
in the centre of the dash panel ⇒ page 256 .
2.20 Removing and installing taxi sign switch
- E138-
Note
♦ The taxi sign switch - E138- is installed in the switch unit in the
centre of the dash panel.
♦ It is removed and installed in the same way as all other buttons
in the centre of the dash panel ⇒ page 256 .
2. Controls 255
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Electrical system - Edition 04.2019
2.21 Removing and installing buttons in cen‐
tre of dash panel
Note
n AG. Volkswagen AG do
♦ The procedure for removal and installation is the same
olks
wage for all es n
ot g
buttons and is therefore described for just one d by button.
V ua
ran
ise
r tee
♦ The button layout in the centre of the dash
ut
ho panel may vary or
depending on the vehicle equipmentssor type of heating or air
a ac
conditioning system.
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1 - Start/stop operation switch - E693- ⇒ page 252
erm
ab
ility
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2 - Front passenger side airbag deactivated warning lamp - K145-
wit
, is n
⇒ page 253
h re
hole
spec
3 - Hazard warning light switch - EX3- ⇒ page 257
es, in part or in w
t to the co
4 - Parking aid button - E266- ⇒ page 253
5 - Heated windscreen button - E627- ⇒ page 254
rrectness of i
6 - Heated rear window switch - E15- ⇒ page 253 or engine run-
on
l purpos
7 - TCS and ESP button - E256- ⇒ page 252
nf
ercia
8 - Rear differential lock switch - E121- ⇒ page 254 : if vehicle is
orm
designed to be used as a taxi, taxi sign switch - E138- is installed
m
atio
m
here
o
n in
or c
thi
9 - Hill descent control button - E618- ⇒ page 255 : if vehicle is
te
sd
a
designed to be used as a taxi, interior light switch (taxi) - E115-
iv
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is installed here
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10 - Left sliding door button - E442- ⇒ page 255 or ventilation
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11 - Button to deactivate sliding door - E443- ⇒ page 255 or ven‐
ht
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12 - Right sliding door button - E442- ⇒ page 255
Special tools and workshop equipment required
♦ Removal wedge - 3409-
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove radio trim ⇒ General body repairs, interior; Rep. gr.
68 ; Centre console; Removing and installing trim for operating
and display unit .
256 Rep. gr.96 - Lights, bulbs, switches - interior
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Electrical system - Edition 04.2019
– Reach through opening next to radio/navigation system and
press out required button -1- from mounting frame in direction
of -arrow-. Move button lightly up and down to enable the
spring clips of the button to release from the fastener.
– Release and disconnect electrical connector -2-.
n AG. Volkswagen AG do
Installing lkswage es n
o ot g
byV ua
ed ran
Install in the reverse order oofr removal. When doing this, note the
is tee
following: auth or
ac
ss
Following installation, check whether all involved switches are
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e
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pt
functioning correctly.
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erm
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ility
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2.22 Removing and installing hazard warning
wit
, is n
h re
light switch - EX3-
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ The hazard warning light switch - EX3- is installed in the switch
unit in the centre of the dash panel.
l purpos
♦ It is removed and installed in the same way as all other buttons
in the centre of the dash panel ⇒ page 256 .
nform
mercia
at
2.23 Removing and installing buttons for seat
om
ion
c
heating -E653- / -E654-
in t
or
his
ate
do
riv
The buttons for seat heating -E653- / -E654- are part of the op‐
p
cum
or
erating and display unit for the air conditioning or Climatronic
f
en
ng
system ⇒ Heating, ventilation, air conditioning; Rep. gr. 87 ; Op‐
t.
yi Co
op
erating and display unit; Overview of fitting locations - operating C py
t. rig
gh
and display unit .
ht
pyri by
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co lksw
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2.24 Removing and installing glove compart‐
cted agen
Prote AG.
ment light switch - E26-
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove glove compartment ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers; Removing and installing
glove compartment .
– Release locking lugs -arrows- and remove switch from glove
compartment.
Installing
Install in reverse order of removal.
2. Controls 257
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Electrical system - Edition 04.2019
2.25 Removing and installing mirror adjust‐
ment switch - E43- / -E168-
Caution
When removing and installing components that are in view
(switches, covers, trim and so on), mask off areas in which
tools ( removal wedge - 3409- , screwdriver) are used to lever
out those components using commercially available masking
tape.
AG. Volkswagen AG d
Special tools and workshop equipment required lksw
agen oes
not
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by
♦ Removal wedge - 3409- rised ara
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un
pt
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ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
l purpos
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
nform
ercia
– Carefully lever out mounting frame -2- using removal wedge -
m
a
3409- .
com
tion in
r
te o
thi
s
iva
do
r
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cum
fo
en
ng
t.
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Cop py
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pyri by
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by c lksw
cted agen
Prote AG.
– Release and separate electrical connectors -2 to 4- and re‐
move from mounting frame -1-.
258 Rep. gr.96 - Lights, bulbs, switches - interior
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Electrical system - Edition 04.2019
Volkswa
– Release locking lugs -arrows- and remove mirror ageadjustment
n AG. gen AG
does
ksw
switch - E43- -1- from mounting frame -2-.
by Vol not
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Installing oris tee
th or
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Installation is carried out in the reverse
ss sequence of removal.
ce
le
un
pt
an
d
itte
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ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
2.26 Removing and installing operating unit
rrectness of i
for window regulator in driver door -
E512-
l purpos
nform
ercia
Caution
m
a
com
ti
When removing and installing components that are in view
on in
(switches, covers, trim and so on), mask off areas in which
r
te o
thi
tools ( removal wedge - 3409- , screwdriver) are used to lever
s
iva
do
out those components using commercially available masking
r
rp
cum
tape.
fo
en
ng
t.
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Cop py
t. rig
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Special tools and workshop equipment required pyri by
Vo
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by c lksw
cted agen
♦ Removal wedge - 3409- Prote AG.
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Carefully lever out mounting frame -2- using removal wedge -
3409- .
2. Controls 259
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Electrical system - Edition 04.2019
– Release and separate electrical connectors -2 - 4- and remove
from mounting frame -1-.
– Release locking lugs -arrows- and remove operating unit for
window regulator in driver door - E512- / -E168- -1- from
mounting frame -2-.
Installing
Installation is carried out in the reverse sequence of removal.
2.27 Removing and installing window regula‐ olkswagen AG
en AG. V
tor switch in front passenger door - y Volkswag does
not
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E107- orisedb ara
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s
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e
Note
nl
pt
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♦ The procedure for removal and installation of the window reg‐
erm
ab
ility
ulator switch in front passenger door - E107- is basically the
ot p
same for the window regulator switch in driver door - E512- .
wit
, is n
h re
hole
♦ Removing and installing operating unit for window regulator in
spec
driver door - E512- ⇒ page 259 .
es, in part or in w
t to the co
2.28 Removing and installing driver side in‐
terior locking button for central locking
rrectness of i
system - E308-
l purpos
nf
ercia
Caution
orm
m
atio
m
When removing and installing components that are in view
o
n in
c
(switches, covers, trim and so on), mask off areas in which
or
thi
tools ( removal wedge - 3409- , screwdriver) are used to lever
te
sd
iva
out those components using commercially available masking
o
r
rp
cu
tape.
o
m
f
en
ng
t.
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Cop py
t. rig
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Special tools and workshop equipment required
ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
260 Rep. gr.96 - Lights, bulbs, switches - interior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
♦ Removal wedge - 3409-
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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un
pt
an
d
itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
urposes, in part or in wh
Removing
t to the co
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
rrectne
– Carefully lever out mounting frame -2- using removal wedge -
3409- .
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
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t.
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Cop py
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rig ht
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– Release and separate electrical connectors -2 - 4- and remove cted agen
Prote AG.
from mounting frame -1-.
– Release locking lugs -arrows- and remove driver side interior
locking button for central locking system - E308- / -E168- -1-
from mounting frame -2-.
Installing
Installation is carried out in the reverse sequence of removal.
2. Controls 261
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Electrical system - Edition 04.2019
2.29 Removing and installing rear lid remote
release button - E233-
AG. Volkswagen AG d
agen oes
olksw not
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Note ed by gu
ara
ris nte
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ut
Removal and installation are described for left-hand
ss a drive vehi‐ ra
c
cles. Removal and installation for right-hand drive vehicles is
ce
e
nl
similar.
pt
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erm
ab
Removing
ility
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wit
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– Remove front door trim panel ⇒ General body repairs, interior;
h re
Rep. gr. 70 ; Front door trim panels; Removing and installing
hole
spec
front door trim panel .
es, in part or in w
t to the co
Note
rrectness of i
For greater clarity, the door trim is not shown.
l purpos
– Using a small screwdriver, release fasteners -2- on both sides.
nform
ercia
– Pull rear lid remote release button - E233- -3- out of trim -1-.
m
at
om
– Release and separate electrical connector on rear lid remote
ion
c
release button - E233- -3-.
in t
or
his
ate
Installing
do
priv
cum
or
Install in the reverse order of removal, observing the following:
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ng
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– Perform functional check. C py
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2.30 Removing and installing door contact
lksw
cted agen
Prote AG.
switch -F2- / -F3-
Note
♦ The door contact switches for the front doors are integrated in
each of the door locks and cannot be renewed individually.
♦ If the door contact switch is defective, the entire door lock must
be renewed ⇒ General body repairs, exterior; Rep. gr. 57 ;
Door components; Removing and installing door lock .
2.31 Removing and installing rear door con‐
tact switches -F10- / -F11-
Note
♦ On vehicles with electric sliding door, the door contact switch
is integrated in the door lock and cannot be renewed individ‐
ually.
♦ The complete door lock must always be renewed if the door
contact switch is defective.
♦ Renew door lock ⇒ General body repairs, exterior; Rep. gr.
58 ; Sliding door; Assembly overview - sliding door .
262 Rep. gr.96 - Lights, bulbs, switches - interior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
agen
AG. Volkswagen AG d
oes Electrical system - Edition 04.2019
o lksw not
y V gu
b ara
A conventionally
rise
d
designed door contact switch is fitted nteon vehicles
with noauelectric
tho
sliding doors, no electric sliding door closing eo
ra aid
and noss anti-theft alarm. c
ce
e
nl
Fitting location of door contact switch -arrow- in C-pillar.
pt
du
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itte
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erm
ab
ility
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Note
wit
, is n
h re
Due to double panels in the area of the C-Pillar, the door contact
hole
spec
switch can only be removed from the outside. During disassem‐
es, in part or in w
bly, the retaining clips of the door contact switch retaining ring are
t to the co
usually destroyed, so that the retaining ring must be renewed.
rrectness of i
Removing
l purpos
– Remove side panel trim on side of vehicle where door contact
switch to be removed is located ⇒ General body repairs, in‐
terior; Rep. gr. 70 ; Interior trim; Overview of fitting locations
nf
ercia
- interior trim .
orm
m
atio
om
– Release and disconnect connector -arrow- from door contact
n in
or c
switch.
thi
te
sd
iva
– Pull door contact switch completely out of body aperture.
o
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f
en
ng
Installing
t.
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Cop py
In a new door contact switch, the retaining ring and the boot are
t. rig
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yri
already fitted to the switch. p by
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cted agen
– Guide wire of door contact switch through body aperture to
Prote AG.
electrical connector.
– Connect and engage connector -arrow-.
– Insert door contact switch into body aperture and attach re‐
taining ring. The retaining ring fits into the body aperture only
in a particular position.
– The switch is adjusted using the fine locking ribs on its surface
-arrow- (illustrated here without boot). Adjust door contact
switch using detent setting so that contact switch opens circuit
properly when sliding door is closed.
– Install side panel trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Trims, interior; Overview of fitting locations - interior
trim .
2. Controls 263
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Electrical system - Edition 04.2019
2.32 Removing and installing release button
for rear lid lock cylinder - F248-
Note
♦ The release button for rear lid lock cylinder is used to open the
rear lid electrically from the inside. agen
AG. Volkswagen AG d
oes
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♦ The button is installed in the lower rear lid trim on vehicles e d with
b gu
ara
central locking system and electrically operated rear horis
lid. nte
eo
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ss c
Removing
ce
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nl
pt
du
an
– Switch off ignition and all electrical equipment and then re‐ itte
y li
erm
move ignition key.
ab
ility
ot p
– Remove rear lid lower trim ⇒ General body repairs, exterior;
wit
, is n
Rep. gr. 70 ; Luggage compartment trim; Removing and in‐
h re
hole
stalling rear lid lower trim .
spec
es, in part or in w
– Press fasteners -arrows- and remove release button for rear
t to the co
lid lock cylinder - F248- -1- from trim -2-.
Installing
rrectness of i
Installation is carried out in the reverse sequence of removal.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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2.33 Removing and installing rear lid closure
n
t.
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op py
button - E574-
. C rig
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copy Vo
Removing
by lksw
cted agen
Prote AG.
– Remove lower rear lid trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Luggage compartment trims; Removing and in‐
stalling lower rear lid trim .
– Press catches -arrows-.
– Remove rear lid remote release button - E574- -1- from trim.
Installing
Install in the reverse order of removal, observing the following:
– Perform functional check.
2.34 Removing and installing rear lid warning
buzzer - H32-
Removing
– Remove lower rear lid trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Luggage compartment trims; Removing and in‐
stalling lower rear lid trim .
264 Rep. gr.96 - Lights, bulbs, switches - interior
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Electrical system - Edition 04.2019
– Disconnect electrical connector -1-.
– Lever off spreader rivets -2-.
– Remove rear lid warning buzzer - H32- -3-.
Installing
Install in the reverse order of removal, observing the following:
– Perform functional check.
2.35 Removing and installing rear lid contact
switch
Rear lid contact switch - F111- and luggage compartment light
switch - F5- are integrated in rear lid lock and cannot be renewed
individually.
If the light switch for luggage compartment - F5- or contact switch
in rear lid - F111- are found to be defective, the complete rear lid
lock must always be renewed.
– Removing and installing rear lid lock ⇒ General body repairs,
exterior; Rep. gr. 55 ; Rear lid; Removing and installing rear
lid lock .
2.36 Removing and installing vanity mirror
contact switch -F147- / -F148-
Note
AG. Volkswagen AG d
agen o
♦ The vanity mirror
Volcontact switches are integrated
ksw es n
ot g in the sun
visor and cannot
se
db
y
be renewed individually. ua
ran
o ri tee
♦ If the vanity
auth
mirror contact switch is defective, the entireor asun
visor shas
s
to be renewed ⇒ General body repairs, interior; Rep. c
ce
le
gr. 68 ; Equipment; Removing and installing sun visor .
un
pt
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ab
2.37 Removing and installing sliding sunroof
pe
ility
ot
adjustment regulator - E139-
wit
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
When removing and installing components that are in view
(switches, covers, trims etc.), mask off areas in which tools
rrectness of i
(plastic wedge, screwdriver) are used to lever out those com‐
ponents using masking tape.
l purpos
nform
ercia
Special tools and workshop equipment required
m
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
2. Controls 265
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Electrical system - Edition 04.2019
♦ Removal wedge - 3409-
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Carefully lever trim of sliding sunroof adjustment regulator -
E139- out of mounting frame.
AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
– Release and disconnect connectors -arrows-. rised
nte
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ss c
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nl
pt
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erm
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ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Release locking lugs -arrows- and remove sliding sunroof ad‐
justment regulator - E139- from mounting frame.
l purpos
Installing
nform
ercia
Installation is carried out in the reverse sequence of removal.
m
at
om
ion
c
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or
his
ate
do
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cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
266 Rep. gr.96 - Lights, bulbs, switches - interior
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
2.38 Removing and installing front interior
light/readingagelight
n AG. Volkswagen AG do
w es n
olks o
Removing and installing
edb
y V front interior light/reading light
t gu
ara
⇒ page 231 . horis nte
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au ac
2.39 ss Removing and installing rear interior
ce
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nl
light/reading light
pt
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erm
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Removing and installing rear interior light/reading light
ility
ot p
⇒ page 237 .
wit
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h re
2.40 Removing and installing front reading
hole
spec
light button -E633- / -E634- and button
es, in part or in w
t to the co
for central deactivation of interior light
rrectness of i
Note
l purpos
The front reading light button -E633- / -E634- and the button for
central deactivation of the interior light form one component and
nf
ercia
o
cannot be renewed individually.
rm
m
atio
om
n in
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Caution
thi
te
sd
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When removing and installing components that are in view
o
m
f
en
ng
(switches, covers, trims etc.), mask off areas in which tools
t.
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(plastic wedge, screwdriver) are used to lever out those com‐ Cop py
t.
ponents using masking tape.
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pyri by
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co lksw
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cted agen
Prote AG.
Special tools and workshop equipment required
♦ Removal wedge - 3409-
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
2. Controls 267
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Electrical system - Edition 04.2019
n AG. Volkswagen AG do
– Carefully lever cover next to switch element for interior and olks
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reading light out of mounting frame. db
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ris tee
Only vehicles with electric sunroof tho or
au ac
ss
– Remove cover with sliding sunroof adjustment regulator -
ce
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nl
E139- ⇒ page 265 .
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Continued for all vehicles
erm
ab
ility
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wit
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h re
hole
spec
es, in part or in w
t to the co
– Carefully push switch element for interior and reading light out
of mounting frame from behind.
rrectness of i
l purpos
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orm
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n in
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– Push connector and wire upwards out of retainer -arrow-. rig ht
py by
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Prote AG.
Only vehicles with interior monitoring
– Remove right ultrasonic sensor for anti-theft alarm system -
G171- -1- and left ultrasonic sensor for anti-theft alarm system
- G170- -2- from their retainer.
Note
When installing the right ultrasonic sensor for anti-theft alarm
system - G171- and the left ultrasonic sensor for anti-theft alarm
system - G170- it is permissible to inter-change them.
Continued for all vehicles
268 Rep. gr.96 - Lights, bulbs, switches - interior
AG. Volkswagen AG d
agen oes
olksw not
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Californiaed 2016 ➤ , Caravelle 2016 ➤ , Multivan
b ara
nte
2016 ➤ , Transporter 20 ...
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tho Electricale o system - Edition 04.2019
au ra
c
ss
– Release and disconnect connector -arrows-.
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– Release locking lugs -arrows- and pull switch element out of
nform
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frame.
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These switches cannot be renewed individually. In the event of
om
io
repair, always renew complete switch element.
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Installation is carried out in the reverse sequence of removal.
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2.41 Controls in interior, Business
⇒ “2.41.1 Removing and installing seat adjustment switch unit,
rotating seats, as of model year 2012”, page 269
⇒ “2.41.2 Removing and installing seat adjustment switch unit,
double seat row, as of model year 2012”, page 270
⇒ “2.41.3 Removing and installing seat heating switch, double
seat row, as of model year 2012”, page 270
⇒ “2.41.4 Notes on fault finding - double seat row”, page 271
2.41.1 Removing and installing seat adjust‐
ment switch unit, rotating seats, as of
model year 2012
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove trim with switch unit from rotating seat ⇒ Rep. gr.
72 .
– Unclip seat adjustment control elements -2- from switch unit.
Note
♦ It is not possible to remove the control elements -2- from the
switch unit without damaging them.
♦ When removing the control elements, the complete seat ad‐
justment switch unit must be renewed.
♦ The illustration shows the arm rest -1- for rear seat adjustment.
2. Controls 269
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Electrical system - Edition 04.2019
– Remove screws -2-.
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– Remove seat adjustment
Vol
ksw switch unit from trim.
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Install in the au r
ss reverse order of removal, observing the following:ac
ce
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nl
– When installing, fit in the same position all cable ties and in‐
pt
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sulation materials that were loosened or cut during removal.
itte
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t to the co
2.41.2 Removing and installing seat adjust‐
ment switch unit, double seat row, as of
rrectness of i
model year 2012
l purpos
Removing
– Switch off ignition and all electrical equipment and then re‐
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move ignition key.
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– Remove arm rest from double seat row ⇒ Rep. gr. 72 .
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– Unclip seat adjustment control elements -2- from switch unit.
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♦ It is not possible to remove the control elements -2- from the
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switch unit without damaging them.
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Prote AG.
♦ When removing the control elements, the complete seat ad‐
justment switch unit must be renewed.
– Remove screws -1-.
– Remove seat adjustment switch unit -2- from arm rest.
Installing
Install in the reverse order of removal, observing the following:
– When installing, fit in the same position all cable ties and in‐
sulation materials that were loosened or cut during removal.
2.41.3 Removing and installing seat heating
switch, double seat row, as of model
year 2012
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
270 Rep. gr.96 - Lights, bulbs, switches - interior
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Electrical system - Edition 04.2019
– Remove arm rest from double seat row ⇒ Rep. gr. 72 .
– Remove screws -1-.
– Remove switch for heated seats - E73- from arm rest
Installing
Install in the reverse order of removal, observing the following:
– When installing, fit in the same position all cable ties and in‐
sulation materials that were loosened or cut during removal.
2.41.4 Notes on fault finding - double seat row
When trying to locate the cause of faults in the vehicle, it is pos‐
sible to isolate the double seat row entirely from the vehicle's
electrical system by unplugging the power supply central plug-in
connection under the double seat row. This enables a faulty elec‐
trical system in the double seat row to be quickly ruled out as the
source of the fault or identified as a possible cause.
– Unclip front left trim under double seat row ⇒ General body
repairs, interior; Rep. gr. 72 ; Rear seats, Business; Removing n AG. Volkswagen AG do
and installing lower trim of rear bench seat . olks
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The power supply central plug-in connection -1- isrilocated
se
d on the nte
left under the double seat row. For further information
utho
on fault eo
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a
finding see also ⇒ Current flow diagrams, Electrical
ss fault finding c
and Fitting locations.
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2. Controls 271
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Electrical system - Edition 04.2019
3 Anti-theft alarm
⇒ “3.1 Assembly overview - interior monitor”, page 272
⇒ “3.2 Removing and installing alarm horn H12 ”, page 273
⇒ “3.3 Removing and installing anti-theft and tilt system control
unit ”, page 274
⇒ “3.4 Removing and installing interior monitor send and receive
module 2 G305 with three ultrasonic sensors”, page 277
Volkswa
⇒ “3.5 Removing and installing deactivation
wage button for vehicle
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clination sender”, page 278 Volks t gu
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3.1 Assemblyauoverview - interior monitor
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Fault detection and fault display
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Anti-theft and tilt system control unit - J529- is equipped with self-
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diagnosis to facilitate fault finding ⇒ Vehicle diagnostic tester.
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Depending on vehicle equipment, the following components are
wit
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installed:
h re
hole
spec
es, in part or in w
1 - Alarm horn - H12-
t to the co
❑ Installed in plenum
chamber.
rrectness of i
❑ Removing and installing
⇒ page 273
l purpos
❑ Securing bolt on retain‐
er: 6 Nm
nf
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or
❑ Self-locking nut on re‐
m
m
atio
tainer: 5 Nm
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2 - Front passenger door con‐
thi
e
tact switch - F3-
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❑ In front passenger side
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central locking lock unit
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- F221- . t. Cop py
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❑ Removing and installing
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door lock ⇒ General
co Vo
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body repairs, exterior;
agen
Prote AG.
Rep. gr. 57 ; Door com‐
ponents; Removing and
installing door lock
3 - Rear right door contact
switch - F11-
❑ In rear right central lock‐
ing lock unit - F223- .
❑ Removing and installing
door lock ⇒ General
body repairs, exterior;
Rep. gr. 58 ; Door com‐
ponents; Removing and
installing door lock
4 - Anti-theft and tilt system
control unit - J529- with vehicle
inclination sender - G384- and
interior monitor send and re‐
ceive module 1 - G303- with
left ultrasonic anti-theft alarm
sensor - G170- and right ultrasonic anti-theft alarm sensor - G171-
❑ Installed behind front roof console.
272 Rep. gr.96 - Lights, bulbs, switches - interior
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Electrical system - Edition 04.2019
❑ Removing and installing ⇒ page 274
❑ Coding ⇒ Vehicle diagnostic tester
5 - Interior monitor send and receive module 2 - G305- with 3 ultrasonic sensors
❑ Installed at rear in roof headliner.
❑ Removing and installing ⇒ page 277
❑ Adapting sensitivity ⇒ Vehicle diagnostic tester
6 - Rear lid contact switch - F111-
❑ Installed in bonnet lock
❑ Removing and installing ⇒ page 265
7 - Rear left door contact switch - F10-
❑ In rear left central locking lock unit - F222- .
❑ Removing and installing door lock ⇒ General body repairs, exterior; Rep. gr. 58 ; Door components;
Removing and installing door lock
8 - Door contact switch, driver side - F2-
❑ In driver side central locking lock unit - F220- .
❑ Removing and geinstalling door
n AG. Volksw lock
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do⇒
es nGeneral body repairs, exterior; Rep. gr. 57 ; Door components;
swa
Removing
y V and installing door lock
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9 - Interior
ho monitoring switch - E183- with warning lamp
ris tee for interior monitoring switch-off - K162- and deactivation
button aut for vehicle inclination sender - E360- with vehicle
or
ac inclination sender warning lamp - K188- each with
ss
button illumination bulb - L76-
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❑ Installed in B-pillar trim on driver side.
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❑ Form one component, can only be replaced together
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❑ Removing and installing deactivation button for vehicle inclination sender - E360- with vehicle inclination
wit
sender warning lamp - K188- ⇒ page 278
is n
h re
ole,
10 - Locking SAFELOCK function warning lamp - K133-
spec
urposes, in part or in wh
❑ Installed in front door trim next to locking bar
t to the co
❑ Install front door trim panel ⇒ General body repairs, interior; Rep. gr. 70 ; Front door trim panels;
Removing and installing front door trim panel
rrectne
11 - Convenience system central control unit - J393-
❑ Installed in seat box on front right.
ss o
❑ Removing and installing ⇒ page 312
cial p
f inform
12 - Bonnet contact switch - F266-
mer
atio
❑ Installed in bonnet lock
om
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❑ Removing and installing ⇒ General body repairs, interior; Rep. gr. 57 ; Central locking; Overview of
i
or
n thi
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fitting locations - central locking
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3.2 Removing and installing alarm horn -
Cop py
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Torque wrench - V.A.G 1331-
Prote AG.
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Plenum chamber cover; Removing and
installing plenum chamber cover .
3. Anti-theft alarm 273
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Electrical system - Edition 04.2019
– Unscrew securing bolt -3- on alarm horn - H12- -1-.
– Release and disconnect connector -2-.
– Remove alarm horn - H12- -1- with bracket.
Installing
Install in the reverse order of removal, observing the following:
Specified torques
♦ ⇒ “3.1 Assembly overview - interior monitor”, page 272
AG. Volkswagen AG d
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3.3 Removing and installing anti-theft and ut
horis nte
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tilt system control unit s a c
s
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nl
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Note
erm
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The anti-theft and tilt system control unit - J529- , the vehicle in‐
, is n
h re
clination sender - G384- and interior monitor send and receive
hole
spec
module 1 - G303- with left ultrasonic sensor for ATA - G170- and
es, in part or in w
right ultrasonic sensor for ATA - G171- are one component and
t to the co
can only be renewed together.
rrectness of i
Caution
l purpos
When removing and installing components that are in view
(switches, covers, trims etc.), mask off areas in which tools
nf
ercia
(plastic wedge, screwdriver) are used to lever out those com‐
rm
ponents using masking tape.
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Special tools and workshop equipment required
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♦ Release lever - T10039-
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274 Rep. gr.96 - Lights, bulbs, switches - interior
n AG. Volkswagen AG do
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California 2016 ➤ y, VCaravelle
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Note
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♦ The anti-theft and tilt system control unit - J529- , the vehicle
ility
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inclination sender - G384- and interior monitor send and re‐
wit
, is n
ceive module 1 - G303- with left ultrasonic sensor for ATA -
h re
G170- and right ultrasonic sensor for ATA - G171- are one
hole
spec
component and can only be removed and installed together.
es, in part or in w
t to the co
♦ As the vehicle inclination sender - G384- is integrated in the
anti-theft and tilt system control unit - J529- , the anti-theft and
tilt system control unit - J529- must be coded upon renewal
rrectness of i
according to whether it is installed lengthways (Multivan) or
crossways (Transporter) to the direction of travel.
l purpos
Removing
nf
ercia
o
– Switch off ignition and all electrical equipment and then re‐
rm
m
atio
move ignition key.
om
n in
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– Turn or tilt interior mirror -6- downwards.
or
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– Open spectacles compartment -3-.
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Vehicles with auxiliary air heater (then without glasses compart‐
en
ng
t.
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ment)
Co
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Prote AG.
– Remove auxiliary heater operating and display unit - E407-
-1- ⇒ Parking heater, auxiliary heater; Rep. gr. 82 ; Parking
heater/auxiliary heater; Overview of fitting locations - parking/
auxiliary heater .
Continued for all vehicles
– Open cover.
Vehicles with electric sliding roof
– Remove cover with sliding sunroof adjustment regulator -
E139- ⇒ page 265 .
Continued for all vehicles
– Remove front interior light - W1- and front passenger reading
light - W13- or driver side reading light - W19- ⇒ page 267 .
3. Anti-theft alarm 275
AG. Volkswagen AG d
agen oes
ksw
California 2016 ➤ , Caravelle 2016 ➤ , Multivan
by
Vol 2016 ➤ , Transporter 20 not
...
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Electrical system - Edition 04.2019 oris e nte
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aut ra
c
– Open cover with the operating buttons,s right ultrasonic sensor
s
ce
e
for anti-theft alarm system - G170- and left ultrasonic sensor
nl
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for anti-theft alarm system - G171- -arrows-.
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, is n
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es, in part or in w
t to the co
rrectness of i
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– Remove securing bolts -arrows-.
nf
ercia
– Unclip front of roof console -1- on windscreen from roof trim
orm
-arrow-.
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Prote AG.
– Push connector and wire upwards out of retainer -1-.
– Then unclip rear of roof console from roof trim -arrows-.
– Push cover with the operating buttons, left ultrasonic sensor
for anti-theft alarm system - G170- -3- and right ultrasonic
sensor for anti-theft alarm system - G171- -2- into the roof
console.
Caution
The roof console -1- now hangs on the wiring harness. Proceed
with caution to prevent damaging the attachments and cables.
276 Rep. gr.96 - Lights, bulbs, switches - interior
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Electrical system - Edition 04.2019
AG. Volkswagen
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– Release and disconnect connector -5- on anti-theft ed
band
y V
tilt ua
ran
system control unit - J529- -4-. oris tee
th or
au ac
– Remove right ultrasonic sensor for anti-theft
ss alarm system -
G171- -2- and left ultrasonic sensor for anti-theft alarm system
ce
le
un
pt
- G170- -3- from their retainers.
an
d
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ab
pe
ility
Note
ot
wit
, is n
h re
hole
When installing the right ultrasonic sensor for anti-theft alarm
spec
system - G171- and the left ultrasonic sensor for anti-theft alarm
es, in part or in w
t to the co
system - G170- it is permissible to interchange them.
– Unclip anti-theft and tilt system control unit - J529- -4- from its
rrectness of i
bracket -arrows- on roof console -1-.
l purpos
Installing
Installation is carried out in the reverse sequence of removal.
nform
ercia
If the anti-theft and tilt system control unit - J529- has been re‐
m
a
com
newed, the interior monitoring must be coded ⇒ Vehicle diagnos‐
tion in
tic tester.
r
te o
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s
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3.4 Removing and installing interior monitor
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send and receive module 2 - G305- with
ng
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three ultrasonic sensors
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Caution
Prote AG.
When removing and installing components that are in view
(switches, covers, trims etc.), mask off areas in which tools
(plastic wedge, screwdriver) are used to lever out those com‐
ponents using masking tape.
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Carefully release catches in moulded headliner -arrows- using
a screwdriver.
– Take bracket for interior monitor send and receive module 2 -
G305- with the three ultrasonic sensors out of moulded head‐
liner.
3. Anti-theft alarm 277
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– Release and disconnect connector -2- on interior monitor send
and receive module 2 - G305- -1-.
– Unclip interior monitor send and receive module 2 - G305-
from the 4 retainers -arrows-. n AG. Volkswagen AG do
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h re
– Unclip sensor cables from cable guides and pull out sensors
hole
spec
-1 to 3-.
es, in part or in w
t to the co
Installing
Install in the reverse order of removal. When doing this, note the
following:
rrectness of i
– Install sensors -1 to 3- in sequence shown in illustration and
l purpos
clip cables into cable guides.
nf
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or
Note
m
m
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c
Adjust sensitivity of ultrasound sensors on interior monitor send
or
thi
e
and receive module 2 - G305- ⇒ Vehicle diagnostic tester.
t
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3.5 Removing and installing deactivation
t.
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Cop py
button for vehicle inclination sender
t. rig
gh ht
pyri by
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co lksw
by
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Prote AG.
Note
♦ Different components may be installed depending on the ve‐
hicle equipment level.
♦ The interior monitoring switch - E183- with warning lamp for
interior monitoring switch-off - K162- and button illumination
bulb - L76- -upper symbol- and the deactivation button for ve‐
hicle inclination sender - E360- with vehicle inclination sender
warning lamp - K188- and button illumination bulb - L76-
-lower symbol- are installed as one component in the B-pillar
trim on the driver side and can only be renewed together.
Caution
When removing and installing components that are in view
(switches, covers, trims etc.), mask off areas in which tools
(plastic wedge, screwdriver) are used to lever out those com‐
ponents using masking tape.
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
278 Rep. gr.96 - Lights, bulbs, switches - interior
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Electrical system - Edition 04.2019
– Carefully lever out switch using a screwdriver.
– Release and disconnect connector -arrow-.
Installing
Installation is carried out in the reverse sequence of removal. wagen AG. Volkswagen AG doe
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, is n
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es, in part or in w
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3. Anti-theft alarm 279
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AG olkswagen AG d
Electrical system - Edition 04.2019 swagen oes
olk no t gu
yV
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4 Immobiliser ss au ra
c
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⇒ “4.1 General description - immobiliser”, page 280
nl
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⇒ “4.2 Removing and installing immobiliser control unit”,
erm
ab
page 280
ility
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wit
, is n
⇒ “4.3 Adapting immobiliser control unit”, page 280
h re
hole
⇒ “4.4 Removing and installing immobiliser reader coil”,
spec
es, in part or in w
page 280
t to the co
4.1 General description - immobiliser
rrectness of i
The 4th generation immobiliser provides online and download
capabilities. The main component of the fourth generation immo‐
l purpos
biliser is a central database, in which all of the theft-relevant data
from the participating control units is stored. Adapting the control
units associated with the immobiliser is not possible without an
nf
ercia
o
online link to this database.
rm
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Note
thi
te
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For additional information on the procedure for renewing compo‐
o
m
f
nents of the immobiliser and on the required adaptations, refer to
en
ng
t.
yi
the relevant chapters in »Electrical system; General information«
Co
Cop py
⇒ Electrical system; General information; Rep. gr. 96 ; Immobil‐
t. rig
gh ht
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iser .
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Prote AG.
Fault detection and fault display:
The immobiliser is equipped with self-diagnosis, which makes
fault finding easier.
To localise faults, refer to chapter entitled “Vehicle diagnosis,
testing and information system” and use “Guided fault finding”
function.
4.2 Removing and installing immobiliser
control unit
The immobiliser control unit - J362- is integrated in the dash panel
insert. If the control unit is defective, the dash panel insert must
be renewed.
– Removing and installing dash panel insert ⇒ page 50 .
4.3 Adapting immobiliser control unit
– Adapt immobiliser control unit - J362- ⇒ Vehicle diagnostic
tester.
4.4 Removing and installing immobiliser
reader coil
The immobiliser reader coil - D2- is joined to the lock cylinder and
cannot be renewed individually.
– Removing and installing lock cylinder ⇒ page 202 .
280 Rep. gr.96 - Lights, bulbs, switches - interior
n AG. Volkswagen AG do
lkswage es n
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byV ua
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California 2016 ➤ , Caravelle
horis 2016 ➤ , Multivan 2016 ➤ , Transportertee 20 ...
t or
au Electrical system - Edition 04.2019
ac
ss
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nl
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5 Lane change assist
itte
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ab
ility
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⇒ “5.1 Assembly overview - lane change assist”, page 281
wit
, is n
h re
⇒ “5.2 Removing and installing lane change assist warning lamp
hole
in exterior mirror K233 / K234 ”, page 282
spec
es, in part or in w
⇒ “5.3 Removing and installing lane change assist control unit
t to the co
J769 / J770 ”, page 282
⇒ “5.4 Calibrating lane change assist”, page 283
rrectness of i
5.1 Assembly overview - lane change assist
l purpos
nform
ercia
1 - Warning lamp for lane
change assist in exterior mirror
m
at
on front passenger side -
om
ion
K234-
c
in t
or
his
e
❑ Installed in right exterior
at
do
riv
mirror housing.
p
cum
for
❑ Removing and installing
en
ng
t.
yi
⇒ page 282
Co
Cop py
t. rig
gh
2 - Lane change assist control
ht
pyri by
Vo
o
unit 2 - J770-
c by lksw
cted agen
Prote AG.
❑ Slave control unit - right
❑ Removing and installing
⇒ page 282
❑ Calibrating ⇒ page 288
❑ Securing bolt: 3.5 Nm
3 - Lane change assist control
unit - J769-
❑ Master control unit - left
❑ Removing and installing
⇒ page 282
❑ Calibrating ⇒ page 288
❑ Securing bolt: 3.5 Nm
4 - Warning lamp for lane
change assist in exterior mirror
on driver side - K233-
❑ Installed in left exterior
mirror housing.
❑ Removing and installing
⇒ page 282
5 - Onboard supply control unit
- J519-
❑ Function control of rain/
light sensor for bright‐
ness regulation of warning lamps in exterior mirror
❑ Removing and installing ⇒ page 313
5. Lane change assist 281
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Electrical system - Edition 04.2019
5.2 Removing and installing lane change
assist warning lamp in exterior mirror -
K233- / -K234-
Removal and installation of the lane change assist warning lamps
in exterior mirror driver side - K233- and lane change assist warn‐
ing lamps in exterior mirror front passenger side - K234- is carried
out in the same manner and is described in the following illustra‐
tions for just one side.
Fitting location of warning lamp for lane change assist in exterior
mirror -arrow-
Note
The brightness of the warning lamps depends on the ambient
brightness and is controlled by the rain and light sensor.
Special tools and workshop equipment required
♦ Removal wedge - 3409-
AG. Volkswagen AG d
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olksw not
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Removing horis nte
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– Switch off ignition and all electrical equipment
ss and then re‐ c
move ignition key.
ce
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nl
pt
du
an
itte
– Using removal wedge - 3409- , carefully remove warning lamp
y li
erm
ab
from mirror housing at position marked with -arrow-.
ility
ot p
– Release and separate electrical connector on warning lamp.
wit
, is n
h re
hole
Installing
spec
es, in part or in w
Install in the reverse order of removal. When doing this, note the
t to the co
following:
rrectness of i
Note
l purpos
In the event of one of more defective LEDs, the lane change assist
warning lamp in exterior mirror must be replaced completely.
nform
mercia
at
om
io
5.3 Removing and installing lane change
n
c
in t
or
assist control unit -J769- / -J770-
his
ate
do
priv
cum
The lane change assist control unit - J769- left and lane change
for
en
g
assist control unit 2 - J770- right is joined to the relevant radar
n
t.
yi Co
op
sensor to form one unit for each side respectively. The lane C py
ht. rig
change assist control units can be found at the rear of vehicle on rig ht
py by
the left and right behind the tail light cluster cover. co Vo
by lksw
cted agen
Prote AG.
282 Rep. gr.96 - Lights, bulbs, switches - interior
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Electrical system - Edition 04.2019
Removing
Note
Removal and installation of left lane change assist control unit -
J769- are described in the following; removal and installation of
right lane change assist control unit 2 - J770- are carried out in
the same manner.
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove end piece beneath tail light cluster ⇒ General body
repairs, exterior; Rep. gr. 63 ; Rear bumper; Assembly over‐
view - bumper cover .
– Release and disconnect connector -arrow- on control unit.
AG. Volkswagen AG d
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olksw not
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– Unscrew securing bolt -arrow- and remove lane change
thor assist eo
control unit from bracket. s au ra
c
s
ce
le
Installing
un
pt
an
d
itte
y li
Install in the reverse order of removal. When doing this, note the
rm
ab
following:
pe
ility
ot
wit
– On completion of assembly work, the lane change assist sys‐
, is n
h re
tem (Side Assist) must be calibrated ⇒ page 283 .
hole
spec
es, in part or in w
t to the co
Note
♦ If both lane change assist control units or just lane change
rrectness of i
assist control unit - J769- left (master) require changing, the
l purpos
lane change assist system must first be coded on completion
of the assembly work and parametrised ⇒ Vehicle diagnostic
tester. The system is then calibrated ⇒ page 283 .
nform
ercia
♦ If just lane change assist control unit 2 - J770- right (slave)
m
requires changing, the lane change assist system only has to
com
tion in
be calibrated on completion of assembly work ⇒ page 283 .
r
te o
thi
s
iva
do
Specified torques
r
rp
cum
fo
en
♦ ⇒ “5.1 Assembly overview - lane change assist”, page 281
ng
t.
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Cop py
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gh
5.4 Calibrating lane change assist
ht
pyri by
Vo
co lksw
by
cted agen
⇒ “5.4.1 Measurement location”, page 283
Prote AG.
⇒ “5.4.2 Preparatory measures for calibration”, page 284
⇒ “5.4.3 Calibrating lane change assist control unit J769 / J770 ”,
page 288
5.4.1 Measurement location
5. Lane change assist 283
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Electrical system - Edition 04.2019
1 - Volkswagen badge
❑ Laser pointer aimed at
centre of Volkswagen
badge
2 - Wheel centre mounting -
VAS 6350/1-
❑ With wheel bolt adapter
AF 19 mm and measur‐
ing paddle
3 - Stop bracket
❑ To support spacing la‐
ser -VAS 6350/2- for
distance measurement
❑ Distance from wheel
centre mountings -VAS
6350/1- on rear wheels:
Dimension -a- = 1700 ±
2 mm.
4 - Spirit level
❑ On calibration unit - VAS
6350- AG. Volkswagen AG d
agen oes
❑ To check horizontal po‐ olksw not
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sition of calibration unit - ise
d b ara
nte
VAS 6350- uthor eo
a ra
s c
5 - Calibration unit - VAS 6350- s
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pt
du
6 - Plastic foot
an
itte
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❑ Qty. 3
erm
ab
ility
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❑ Adjustable to change
wit
, is n
horizontal position of
h re
calibration unit - VAS
hole
spec
6350-
es, in part or in w
t to the co
7 - Spacing laser - VAS
6350/2-
❑ For distance measure‐
rrectness of i
ment
l purpos
❑ Handling ⇒ Operating instructions
8 - Linear laser - VAS 6350/3-
nf
ercia
❑ With “laser goggles”
rm
m
atio
❑ On calibration unit - VAS 6350-
om
n in
c
❑ Switching on and off ⇒ Operating instructions
or
thi
te
sd
iva
9 - Measuring scale
o
r
rp
cu
o
❑ To position calibration unit for lane change assist -VAS 6350/4-
f
en
ng
t.
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❑ Dimension to be set, measuring point on steel rule = 697 mm t. Cop py
rig
gh ht
10 - Calibration unit for lane change assist -VAS 6350/4- yri
p by
co Vo
by lksw
❑ is changed over from the left to the right-hand side of the measuring field during calibration cted agen
Prote AG.
❑ If assembled correctly, the mains power lead should be fitted to the bottom left of the calibration unit (as
seen facing direction of normal travel)
5.4.2 Preparatory measures for calibration
The lane change assist control unit - J769- left (master) and lane
change assist control unit 2 - J770- right (slave) is joined to the
relevant radar sensor to form one unit for each side respectively.
284 Rep. gr.96 - Lights, bulbs, switches - interior
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Electrical system - Edition 04.2019
They are located behind the end pieces beneath the tail lights and
must be calibrated following:
♦ Removal and installation of one or both lane change assist
control units
♦ Any change in the installation position of a lane change assist
control unit
♦ After removal or installation of one of nthe
AG.covers
Volkswagabove
en AG the
lane change assist control unitolkswage does
no
V t gu
by ara
Extensive preliminary workriis
se required before actual calibration
d
nte
can be carried out usinguvehicle
tho diagnostic tester . eo
ra
a c
ss
Prerequisites:
ce
le
un
pt
an
• Position vehicle on a firm and level surface.
d
itte
y li
rm
ab
• Apply parking brake. Vehicle must not be moved during meas‐
pe
ility
urement.
ot
wit
, is n
h re
• Align front wheels to straight-ahead position – steering wheel
hole
spec
in straight-ahead position.
es, in part or in w
t to the co
• If necessary, remove sticker with metal foil from bumper cover.
• Nobody must be inside vehicle during measurement.
rrectness of i
• Opening and closing the vehicle doors during calibration must
be avoided.
l purpos
nform
ercia
Note
m
a
com
ti
If a fault message appears in the display ⇒ operating instructions
on in
of vehicle diagnostic tester .
r
te o
thi
s
iva
do
r
Special tools and workshop equipment required
rp
cum
fo
en
ng
♦ Calibration unit - VAS 6350-
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Vehicle diagnostic tester
– Connect vehicle diagnostic tester ⇒ page 321 .
– Switch on ignition.
5. Lane change assist 285
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Electrical system - Edition 04.2019
– Attach 3 wheel bolt adapters (19 mm) for wheel securing bolts
to each wheel centre mounting - VAS 6350/1- .
– Insert the measuring paddles in the two wheel centre mount‐
ings -VAS 6350/1- and secure them with the clamping nut.
– Fit the wheel centre mountings - VAS 6350/1- onto the wheel AG. Volkswagen AG d
bolts on both rear wheels. agen oes
olksw not
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d b ara
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Note s au ra
c
s
ce
le
un
pt
♦ The turning centre of the wheel centre mounting must be in
an
d
itte
the turning centre of the wheel.
y li
rm
ab
pe
ility
♦ Place wheel centre mountings - VAS 6350/1- on wheels so
ot
that “anti-theft wheel bolts” are not connected to the wheel
wit
, is n
h re
centre mountings. hole
spec
es, in part or in w
– Set measuring paddles with the help of the clamping nuts in
t to the co
such a way that they can move freely just above the floor.
• The measuring paddles must not be restricted in movement.
rrectness of i
• The measuring paddles must be vertical.
l purpos
– Position the calibration unit - VAS 6350- at a distance of -a- to
nform
ercia
the rear wheels.
m
• Dimension -a- = 1700 ± 2 mm.
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Switch on spacing laser -VAS 6350/2- using ON button.
Display on -VAS 6350/2- :
• “- - - m”
Note
The laser is switched on at the same time.
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Electrical system - Edition 04.2019
– Hold spacing laser -VAS 6350/2- -2- for distance measure‐
ment flush with stop bracket as shown in illustration.
The spacing laser -VAS 6350/2- must be firmly in contact with the
stop bracket when doing this.
– Ensure that the “laser beam” for distance measurement is at
the bottom enlarged part on the measuring paddle -1-.
If this is not the case, the height of the measuring paddles has to
be corrected with the aid of the clamping nuts on the wheel centre
mounting - VAS 6350/1- .
– Now, briefly press ON button to measure distance.
Display on -VAS 6350/2- :
• “1700 m” (specification: 1700 ± 2 mm).
– Repeat the measuring process from the left stop bracket to the
measuring paddle on the rear left wheel.
• Measured distance value must be identical on both sides.
If both measured values are not identical, adjust calibration unit -
VAS 6350- accordingly.
– Attach the calibration unit for lane change assist -VAS 6350/4-
on the rear left on the mounting of the calibration unit - VAS
6350- .
Note
n AG. Volkswagen AG do
wage
If assembled correctly, the mainsy Vpower o lks lead should be fitted eto s no
t gu
the bottom left of the calibration
ir se
d unit
b as seen facing direction of ara
nte
normal travel. tho eo
au ra
ss c
Dimension -a- = 840 mm measured from upper edge of calibration
ce
le
un
pt
unit to workshop floor.
an
d
itte
y li
erm
ab
– The dimension is set with the measuring point -arrow- at the
ility
ot p
base of the calibration unit on the scale of the steel rule -1-.
wit
is n
h re
Setting dimension on left read off on measuring scale -1- =
ole,
697 mm.
spec
urposes, in part or in wh
t to the co
– Connect the calibration unit for lane change assist -VAS
6350/4- to mains voltage.
rrectne
– Align calibration unit - VAS 6350- to horizontal position with
the aid of the vial (sight glass) -arrow- by turning the plastic
feet.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Lane change assist 287
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Electrical system - Edition 04.2019
– Put on “laser protection glasses”.
– Switch on linear laser - VAS 6350/3- on calibration unit - VAS
6350- .
– Align the whole calibration unit - VAS 6350- so that the laser
beam is focused on the rear of the vehicle in the centre above
the VW badge.
– Check the spacing on the left and right again between the stop
brackets of the calibration unit l-ksVAS n AG. Volkswagen AG do
wage 6350- and the measuring
es n
paddles -1- on the wheel mountings.
by
Vo ot g
ua
ed ran
ris tee
• Specification: 1700 u±tho2 mm or
sa ac
Calibrating lane change
s assist control unit ⇒ page 288 .
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
5.4.3 Calibrating lane change assist control
unit -J769- / -J770- rrectness
Note
o
cial p
f inform
Before the actual calibration process of the lane change assist
mer
control units, the calibration unit - VAS 6350- has to be set up as
atio
m
described in chapter
o
n
c
i
or
⇒ “5.4.2 Preparatory measures for calibration”, page 284 .
thi
te
sd
iva
o
pr
Special tools and workshop equipment required
um
r
fo
en
ng
t.
yi
♦ Calibration unit - VAS 6350-
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Vehicle diagnostic tester
During the calibration procedure the following conditions must be
met:
• Vehicle doors must not be opened or closed.
• There should be no-one in the vehicle.
• No-one should pass through the space between the vehicle
and the calibration unit for lane change assist -VAS 6350/4- .
288 Rep. gr.96 - Lights, bulbs, switches - interior
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Electrical system - Edition 04.2019
Procedure
– Switch on the calibration unit for lane change assist -VAS
6350/4- using the mains switch -3-.
• The green LED -1- must light up.
Note
If the red LED -2- lights up: Check the calibration unit for lane
change assist -VAS 6350/4- .
– Connect vehicle diagnostic tester ⇒ page 321 .
– Select option for calibration in “Guided Fault Finding” mode
⇒ Vehicle diagnostic tester.
– Using “GoTo” button, select “Functions/component” and then
the following menu options in succession: G. Volkswage
nA n AG d
wage oes
♦ Body Volks not
gu
by ara
ed
♦ General body repairs thoris nte
eo
au ra
♦ 01 - Self-diagnosis compatible
ss systems c
ce
le
un
pt
♦ Lane change assist
an
d
itte
y li
♦ Functions
rm
ab
pe
ility
ot
♦ Calibration - lane change assist
wit
, is n
h re
– Proceed by following the instructions on the display of vehicle
hole
spec
diagnostic tester .
es, in part or in w
t to the co
During the program sequence you will be requested to change
the calibration unit for lane change assist -VAS 6350/4- from the
rrectness of i
left to the right-hand side of the calibration unit - VAS 6350- .
l purpos
– Switch off the calibration unit for lane change assist -VAS
6350/4- and change to the other side. nform
ercia
Note
m
a
com
tion in
r
If assembled correctly, the mains power lead should be fitted to
te o
thi
the bottom left of the calibration unit as seen facing direction of
s
iva
do
normal travel.
r
rp
cum
fo
en
ng
t.
yi Co
Dimension -a- = 840 mm measured from upper edge of calibration Cop py
unit to workshop floor.
t. rig
gh ht
pyri by
Vo
co
– The dimension is set with the measuring point -arrow- at the
by lksw
cted agen
base of the calibration unit on the scale of the steel rule -1-.
Prote AG.
Setting dimension on right read off on measuring scale -1- =
697 mm.
5. Lane change assist 289
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Electrical system - Edition 04.2019
– Switch on the calibration unit for lane change assist -VAS
6350/4- using the mains switch -3-.
• The green LED -1- must light up.
– Proceed by following the instructions on the display of vehicle
diagnostic tester .
Upon completion of lane change assist system calibration switch
off ignition and disconnect diagnosis connector.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
290 Rep. gr.96 - Lights, bulbs, switches - interior
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Electrical system - Edition 04.2019
6 Front camera for assist systems
The front camera for driver assist systems - R242- , the anti-daz‐
zle interior mirror button - E386- and the main beam assist control
unit - J844- are not available as individual replacement parts.
If these components need to be renewed, the interior mirror - EX5-
must be renewed. A calibration is not required.
Removing
– Remove interior mirror ⇒ General body repairs, interior; Rep.
gr. 68 ; Interior mirror; Removing and installing interior mirror .
Installing
Install in reverse order of removal.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
6. Front camera for assist systems 291
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7 Cigarette lighter, socket
⇒ “7.1 Overview of fitting locations - DC/AC converter with socket,
12 V-230 V”, page 292
⇒ “7.2 Assembly overview - DC/AC converter with socket,
12 V-230 V”, page 293
⇒ “7.3 Assembly overview - cigarette lighter, 12 V socket”,
page 294
⇒ “7.4 Removing and installing cigarette lighter U1 ”, page 294
⇒ “7.5 Removing and installing socket illumination bulb L42 ”,
page 294
⇒ “7.6 Removing and installing rear cigarette lighter illumination
bulb L32 ”, page 294
⇒ “7.7 Removing and installing
wage
nAelectric
G. Volkswsocket
agen AGU ”, page 295
doe
ks s no
Vol t
⇒ “7.8 Removing and
ed installing DC/AC converter with socket,
by gu
ara
12 V-230 V U13
ho ”, page 295
ris nte
e t or
au ac
7.1 ss Overview of fitting locations - DC/AC converter with socket, 12 V-230 V
ce
e
nl
pt
du
an
itte
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1 - AC/DC converter with sock‐
erm
ab
ility
et, 12 V-230 V - U13-
ot p
wit
, is n
❑ In left side panel trim at
h re
rear
hole
spec
❑ Removing and installing
es, in part or in w
t to the co
⇒ page 295
2 - Socket housing with socket
insert
rrectness of i
❑ In left side panel trim at
l purpos
rear
❑ Removing and installing
nform
ercia
socket housing
⇒ page 299
m
at
om
❑ Removing and installing
on
c
socket insert
in t
or
his
e
⇒ page 298
at
do
priv
3 - Socket housing with socket
um
for
en
g
insert
n
t.
yi Co
op
❑ In trim at rear on driver
C py
t. rig
gh
seat
ht
pyri by
Vo
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by c lksw
❑ Removing and installing Prote
cted agen
socket housing
AG.
⇒ page 299
❑ Removing and installing
socket insert
⇒ page 298
4 - AC/DC converter with sock‐
et, 12 V-230 V - U13-
❑ In seat box under driver
seat
❑ Removing and installing
⇒ page 295
5 - Fuses
❑ In relay and fuse carrier,
under driver seat
292 Rep. gr.96 - Lights, bulbs, switches - interior
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❑ Fuse assignment ⇒ page 300
7.2 Assembly overview swage
n A-GDC/AC
. Volkswagenconverter
AG do
es n
k
with socket, y 12 V-230 V
Vol ot g
b ua
ed is
ra nte
or
Overview of fitting locations
au
th . DC/AC converter with socket, 12 V eo
ra
- 230 V, under driver
ss seat c
ce
le
un
pt
an
d
itte
y li
1 - Lower seat pan frame
rm
ab
pe
ility
2 - Bolts
ot
wit
, is n
❑ 4x10
h re
hole
❑ 1.5 Nm
spec
es, in part or in w
t to the co
3 - Bolts
❑ 4x15
❑ 1.5 Nm
rrectness of i
4 - Washers
l purpos
5 - AC/DC converter with sock‐
et, 12 V-230 V - U13-
nform
ercia
❑ Removing and installing
m
a
⇒ page 295
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Cigarette lighter, socket 293
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Electrical system - Edition 04.2019
7.3 Assembly overview - cigarette lighter, 12 V socket
1 - Cigarette lighter socket with
wiring harness
2 - Cigarette lighter
3 - Electric socket
Fitting location (depending on
equipment):
♦ In centre console
♦ In stowage compartment of
C-pillar
♦ In roof trim of pop-up roof
♦ On side of kitchen cabinet
♦ In centre console of two-
seater bench in rear
♦ In luggage compartment
4 - Cigarette lighter socket
Fitting location (depending on
equipment):
♦ In ashtray of centre console
♦ In centre console of two-
seater bench in rear
5 - Clamping sleeve
6 - Light bulb W 5 12V,
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7.4 Removing and installing cigarette lighter
spec
es, in part or in w
- U1-
t to the co
All instructions and notes regarding this chapter are available un‐
der “Electrical system, General information; Repair Group 96;
rrectness of i
Cigarette lighter; Socket”.
l purpos
7.5 Removing and installing socket illumi‐
nation bulb - L42-
nform
ercia
All instructions and notes regarding this chapter are available un‐
m
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com
der “Electrical system, General information; Repair Group 96;
ion in
Cigarette lighter; Socket”.
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7.6 Removing and installing rear cigarette
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Cigarette lighter; Socket”.
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294 Rep. gr.96 - Lights, bulbs, switches - interior
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Electrical system - Edition 04.2019
7.7 Removing and installing electric socket
- U-
All instructions and notes regarding this chapter are available un‐
der “Electrical system, General information; Repair Group 96;
Cigarette lighter; Socket”.
7.8 Removing and installing DC/AC con‐
verter with socket, 12 V-230 V - U13-
7.8.1 Removing and installing DC/AC con‐
verter with socket, 12 V-230 V - U13- ,
under driver seat
WARNING
There is a danger of an electric shock.
♦ In the housing of the DC/AC converter with socket,
12 V - 230 V - U13- there are capacitors that may still be
charged with a residual voltage.
♦ Never open the housing of the DC/AC converter with sock‐
et, 12 V - 230 V - U13- .
♦ The connector, wiring and 230 V socket must never be
repaired.
♦ The complete unit must be replaced if the connector, wir‐
ing and 230 V socket or the AC/DC converter are defec‐
tive. swagen AG. Volkswagen AG do
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Special tools and workshop
utho equipment required eo
ra
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ss
♦ Torque screwdriver - V.A.G 1624-
ce
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un
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♦ Torque wrench - V.A.G 1410-
nform
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7. Cigarette lighter, socket 295
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Electrical system - Edition 04.2019
Removing:
– Unscrew bolts -1-.
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– Switch off ignition. yV
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– Remove second battery - A1- ⇒ page 11 . ir se tee
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– Unclip handbrake lever trim ⇒ Brake system; Rep.
ss gr. 46 ;
Handbrake; Assembly overview - handbrake .
ce
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un
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spec
urposes, in part or in wh
– Disconnect electrical connector -1-.
t to the co
– Open clips -2- on wiring.
– Remove 230 V socket insert ⇒ page 298 .
rrectne
– Remove DC/AC converter with socket, 12 V-230 V - U13-
-3-.
ss o
cial p
f
Installing:
inform
mer
Install in the reverse order of removal, observing the following:
atio
m
– Use washers for lower bolts between DC/AC converter with
o
n
c
i
or
n
socket, 12 V-230 V - U13- and lower seat pan frame
thi
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⇒ page 293 .
sd
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Specified torques
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♦ ⇒ “7.2 Assembly overview - DC/AC converter with socket, Cop py
12 V-230 V”, page 293
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7.8.2 Removing and installing DC/AC con‐
Prote AG.
verter with socket, 12 V-230 V - U13- ,
in side panel trim
WARNING
There is a danger of an electric shock.
♦ In the housing of the DC/AC converter with socket,
12 V - 230 V - U13- there are capacitors that may still be
charged with a residual voltage.
♦ Never open the housing of the DC/AC converter with sock‐
et, 12 V - 230 V - U13- .
♦ The connector, wiring and 230 V socket must never be
repaired.
♦ The complete unit must be replaced if the connector, wir‐
ing and 230 V socket or the AC/DC converter are defec‐
tive.
Special tools and workshop equipment required
296 Rep. gr.96 - Lights, bulbs, switches - interior
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Electrical system - Edition 04.2019
♦ Torque screwdriver - V.A.G 1624-
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Removing:
m
a
– Switch off ignition.
com
tion in
r
– Disconnect second battery - A1- ⇒ page 7 .
te o
thi
s
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do
– Remove middle side panel trim ⇒ General body repairs, inte‐
r
rp
cum
rior; Rep. gr. 70 ; Trims, interior; Removing and installing side
fo
en
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trim .
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– Disconnect electrical connector under foam cover -3-.
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– Remove 230 V socket insert ⇒ page 298 .
– Remove DC/AC converter with socket, 12 V-230 V - U13-
-1-.
Installing:
Install in the reverse order of removal, observing the following:
Specified torques
Component Specified torque
Bolts on AC/DC converter with sock‐ 1.5 Nm
et, 12 V-230 V - U13-
7. Cigarette lighter, socket 297
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
7.9 Removing and installing 230 Vensocket
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insert, under driver seat
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WARNING
wit
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spec
urposes, in part or in wh
♦ In the housing of the DC/AC converter with socket,
t to the co
12 V - 230 V - U13- there are capacitors that may still be
charged with a residual voltage.
rrectne
♦ Never open the housing of the DC/AC converter with sock‐
et, 12 V - 230 V - U13- .
s
♦ The connector, wiring and 230 V socket must never be
s o
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repaired.
f inform
mer
♦ The complete unit must be replaced if the connector, wir‐
atio
ing and 230 V socket or the AC/DC converter are defec‐
om
tive.
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Removing:
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– Switch off ignition.
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– Press catches -1- outwards, and pull 230 V socket insert -2-
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out of trim -3-.
Installing:
Install in reverse order of removal.
7.9.2 Removing and installing 230 V socket
insert, in side panel trim
WARNING
There is a danger of an electric shock.
♦ In the housing of the DC/AC converter with socket,
12 V - 230 V - U13- there are capacitors that may still be
charged with a residual voltage.
♦ Never open the housing of the DC/AC converter with sock‐
et, 12 V - 230 V - U13- .
♦ The connector, wiring and 230 V socket must never be
repaired.
♦ The complete unit must be replaced if the connector, wir‐
ing and 230 V socket or the AC/DC converter are defec‐
tive.
Special tools and workshop equipment required
298 Rep. gr.96 - Lights, bulbs, switches - interior
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Electrical system - Edition 04.2019
♦ Torque screwdriver - V.A.G 1624-
Removing:
– Switch off ignition.
– Remove middle side panel trim ⇒ General body repairs, inte‐
rior; Rep. gr. 70 ; Trims, interior; Removing and installing side
trim .
– Press catches -2- in direction of -arrow A-, and pull 230 V
socket insert -1- in direction of arrow -B- out of socket housing.
Installing:
Install in reverse order of removal.
7.10 Removing and installing 230 V socket
housing
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7.10.1 Removing and installing 230 V socket
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7. Cigarette lighter, socket 299
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en A . Volkswagen A20
G do...
sw es n
Electrical system - Edition 04.2019 y Volk ot g
u b ara
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Removing: au
tho e or
ac
ss
– Switch off ignition.
ce
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un
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an
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Removing and installing 230 V socket insert ⇒ page 298 .
itte
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ab
– Unscrew bolts -2-.
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– Detach socket housing from trim -1-.
h re
ole,
Installing:
spec
urposes, in part or in wh
t to the co
Install in the reverse order of removal, observing the following:
Specified torques
rrectne
Component Specified torque
Bolts on socket housing 1.5 Nm
ss o
cial p
f inform
7.10.2 Removing and installing 230 V socket
mer
atio
housing, in side panel trim
om
n
c
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Special tools and workshop equipment required
thi
te
sd
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o
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♦ Torque screwdriver - V.A.G 1624-
p
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Removing:
– Switch off ignition.
– Remove 230 V socket insert ⇒ page 298 .
– Loosen clips -1-, and remove socket housing -2- from trim
-3-.
Installing:
Install in reverse order of removal.
7.11 Fuses for AC/DC converter with socket,
12 V-230 V - U13-
Fitting locations of fuses for AC/DC converter with socket,
12 V-230 V - U13-
The fuses are located in the relay and fuse carrier under the driver
seat.
Several fuses may be installed here depending on the equipment
level.
300 Rep. gr.96 - Lights, bulbs, switches - interior
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AG. Volkswagen AG d
lksw
agen oes
not Electrical system - Edition 04.2019
Vo gu
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Fuse assignment
horis nte
eo
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1 - 30s A fuse for AC/DC converter with socket, 12 V-230 Vc -
s U13-
at front
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2 - 30 A fuse for AC/DC converter with socket, 12 V-230 V - U13-
y li
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at rear
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7. Cigarette lighter, socket 301
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Electrical system - Edition 04.2019
8 Controls in interior, Business
⇒ “8.1 Removing and installing seat adjustment switch unit, ro‐
tating seats, as of model year 2012, Business”, page 302
8.1 Removing and installing seat adjust‐
ment switch unit, rotating seats, as of
model year 2012, Business
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove trim with switch unit from rotating seat ⇒ Rep. gr.
72 .
– Unclip seat adjustment control elementsV-2- from switch unit.
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♦ It is not possible sto remove the control elements -2- from the
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switch unit without damaging them.
un
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an
d
itte
♦ When removing the control elements, the complete seat ad‐
y li
erm
ab
justment switch unit must be renewed.
ility
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wit
♦ The illustration shows the arm rest -1- for rear seat adjustment.
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Remove screws -2-.
– Remove seat adjustment switch unit from trim.
rrectne
Installing
s
Install in the reverse order of removal, observing the following:
s o
cial p
f in
– When installing, fit in the same position all cable ties and in‐
form
mer
sulation materials that were loosened or cut during removal.
atio
om
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8.2 Removing and installing seat adjust‐ Cop py
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ment switch unit, double seat row, as of
rig ht
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Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove arm rest from double seat row ⇒ Rep. gr. 72 .
302 Rep. gr.96 - Lights, bulbs, switches - interior
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Electrical system - Edition 04.2019
– Unclip seat adjustment control elements -2- from switch unit.
Note
♦ It is not possible to remove the control elements -2- from the
switch unit without damaging them.
♦ When removing the control elements, the complete seat ad‐
justment switch unit must be renewed.
– Remove screws -1-.
– Remove seat adjustment switch unit -2- from arm rest.
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Install in the reverse order of removal, observing
tho the following: eo
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– When installing, fit in the same position
s all cable ties and in‐
ce
le
sulation materials that were loosened or cut during removal.
un
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itte
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ab
ility
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wit
is n
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ole,
spec
urposes, in part or in wh
8.3 Removing and installing seat heating
t to the co
switch, double seat row, as of model
year 2012, Business
rrectne
Removing
ss
– Switch off ignition and all electrical equipment and then re‐
o
cial p
f
move ignition key.
inform
mer
– Remove arm rest from double seat row ⇒ Rep. gr. 72 .
atio
om
n
– Remove screws -1-.
c
i
or
n thi
te
– Remove switch for heated seats - E73- from arm rest
sd
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Installing
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Install in the reverse order of removal, observing the following: Cop py
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– When installing, fit in the same position all cable ties and in‐ py by
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sulation materials that were loosened or cut during removal.
by lksw
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Prote AG.
8. Controls in interior, Business 303
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Electrical system - Edition 04.2019
97 – Wiring agen
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1 Relay carriers, fuse holders, elec‐ ed
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tronics boxes a ra
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⇒ “1.1 Overview of fitting locations - relay carriers, fuse holders,
du
an
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E-boxes”, page 304
y li
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ility
⇒ “1.2 Removing and installing electronics box on left side of en‐
ot p
wit
gine compartment”, page 305
, is n
h re
hole
⇒ “1.3 Removing and installing coupling station in seat box at front
spec
on left”, page 309
es, in part or in w
t to the co
⇒ “1.4 Removing and installing relay carrier and fuse holder in
front seat boxes”, page 310
rrectness of i
⇒ “1.5 Removing and installing relay carrier and fuse holder in
centre console”, page 311
l purpos
⇒ “1.6 Removing and installing coupling station electronics box”,
page 311
nform
ercia
⇒ “1.7 Removing and installing relay carrier and fuse holder in
m
at
om
electronics box”, page 311
ion
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1.1 Overview of fitting locations - relay carriers, fuse holders, E-boxes
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ate
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Prote AG.
304 Rep. gr.97 - Wiring
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Electrical system - Edition 04.2019
1 - Relay carrier and fuse hold‐
er in centre console
❑ Installed behind cover in
the centre under the AG. Volkswagen AG d
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❑ Relay carrier and fuse d by ara
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holder are removed to‐ ut
hor eo
gether ⇒ page 311 ss a ra
c
ce
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2 - Relay carrier in dash panel
nl
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on driver side
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❑ Installed on driver side
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under dash panel
wit
, is n
❑ Dash panel relay carrier
h re
hole
on driver side is part of
spec
onboard supply control es, in part or in w
t to the co
unit bracket and cannot
be removed individually
3 - Relay carrier and fuse hold‐
rrectness of i
er in front seat box
l purpos
❑ Installed on left and/or
right
nf
ercia
❑ Removing and installing
or
⇒ page 310
m
m
atio
m
4 - Coupling station in front left
o
n in
or c
seat box
thi
te
sd
a
❑ With fastening strip “in‐
iv
o
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rp
cu
terface for external use”
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f
UF1
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op
❑ Removing and installing C py
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⇒ page 309
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5 - Fuse holder A - SA- cted agen
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❑ Installed in electronics
box on left in engine
compartment
❑ Access to fuse holder
gained by opening electronics box ⇒ page 305
6 - Relay carriers
❑ Installed in electronics box on left in engine compartment
❑ Access to relay carrier by opening electronics box ⇒ page 305
7 - Relay carriers
❑ Installed in electronics box on left in engine compartment
❑ Access to relay carrier by opening electronics box ⇒ page 305
8 - Fuse holder D - SD-
❑ Installed in electronics box on left in engine compartment
❑ Access to fuse holder possible via separate cover without opening electronics box.
1.2 Removing and installing electronics box
on left side of engine compartment
Removing
Special tools and workshop equipment required
1. Relay carriers, fuse holders, electronics boxes 305
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Electrical system - Edition 04.2019
♦ Torque wrench - V.A.G 1783-
– Remove battery - A- in engine compartment ⇒ page 11 .
– Remove left headlight ⇒ page 118 .
olkswagen AG
– Remove battery partition ⇒ page
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– Remove battery trayse⇒d bpage 15 . ara
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– Turn catches -arrows-
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Prote AG.
306 Rep. gr.97 - Wiring
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Electrical system - Edition 04.2019
AG. Volkswagen AG d
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Note
For reasons of clarity, the area around the electronics box is not shown in the illustration.
– Push locking element on fuse insert -2- in direction of housing
and pull fuse insert upwards out of fuse box -1-.
– Slide fuse carrier -3- sideways out of its position and push
downwards.
– Unscrew the 8 securing bolts -5-.
– Remove upper part of electronics box -4-.
– Release and disconnect connector -6- on engine control unit
-7-.
1. Relay carriers, fuse holders, electronics boxes 307
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Electrical system - Edition 04.2019
AG. Volkswagen AG d
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yri
For reasons of clarity, the area around the electronics box is not shown in the illustration. p by
o Vo
by c lksw
cted agen
Prote AG.
– Unbolt cable (PIN 10) -1- and place aside.
– Unscrew eight securing bolts -2- and remove centre part of
electronics box -3-.
– Press locking element -arrow- of relay carrier -4- and pull car‐
rier upwards.
– Press locking element -arrow- of coupling station -5- and pull
it upwards.
– Release and separate all electrical connectors.
308 Rep. gr.97 - Wiring
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Unbolt wiring from wiring carrier -1- and place to one side.
Note
The numbering on the line carrier is identical to the numbers
shown on the lines.
– Pull engine control unit -2- out of runners.
– Remove all wiring with wiring guides out of lower part of elec‐
tronics box -3- and place to one side.
– Unscrew securing nuts -1- and remove lower part of electron‐
ics box -2-.
Installing
Install in the reverse order of removal. When doing this, note the
following:
Note
♦ The sealing collars of the lines must be inserted into the guides
of the electronics box.
♦ The wires must not be pinched between the upper and lower
parts of the electronics box when they are put together.
Specified torques
Component Specified torque
Bolts securing upper part of electron‐ 6 Nm
ics box (qty. 8)
n AG. Volkswagen AG do
Nut securing cable PIN 10 (B+) 9lkswage
Nm es n
o ot g
byV ua
Nut securing cable PIN 1 (alternator)
ir se
d 20 Nm ran
tee
ho
Bolts securing centre part sof
au elec‐
t
4 Nm or
ac
tronics box (qty. 8) s
ce
le
un
pt
Nuts securing cables PIN 2-9 to ca‐ 4 Nm
an
d
itte
ble holder
y li
erm
ab
Nuts securing upper part of electron‐ 6 Nm
ility
ot p
ics box (qty. 3)
wit
is n
h re
ole,
spec
1.3 Removing and installing coupling sta‐
urposes, in part or in wh
t to the co
tion in seat box at front on left
Special tools and workshop equipment required
rrectne
♦ Torque wrench - V.A.G 1783-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Relay carriers, fuse holders, electronics boxes 309
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
California 2016 ➤ , Caravelle 2016 ➤ , Multivan
rised
2016 ➤ , Transporter 20 ... nte
o eo
Electrical system - Edition 04.2019 aut
h
ra
ss c
ce
e
Removing
nl
pt
du
an
itte
y li
– Disconnect batteries ⇒ page 7 .
erm
ab
ility
ot p
– Remove the front seat ⇒ General body repairs, interior; Rep.
wit
, is n
gr. 72 ; Front seats; Removing and installing front seat .
h re
hole
– Unscrew securing bolt -top arrow- and pull out coupling station
spec
es, in part or in w
-1- from under bracket with cables attached -bottom arrow-.
t to the co
Installing
Install in the reverse order of removal. When doing this, note the
rrectness of i
following: l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
– First insert coupling station -1- underneath -bottom arrow- and
p
cum
or
then secure with securing bolt -top arrow-.
f
en
ng
t.
yi Co
op
Specified torques C py
ht. rig
rig ht
py by
Component Specified torque
co Vo
by lksw
cted agen
Prote AG.
Bolt securing coupling station 2 Nm
1.4 Removing and installing relay carrier
and fuse holder in front seat boxes
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-
Removing
– Disconnect batteries ⇒ page 7 .
– Remove the front seat ⇒ General body repairs, interior; Rep.
gr. 72 ; Front seats; Removing and installing front seat .
310 Rep. gr.97 - Wiring
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Unscrew securing bolts -arrows- and remove relay carrier and
fuse holder with wiring connected.
Installing AG. Volkswagen AG d
agen oes
lksw n t
Install in the reverse
byV
o order of removal. When odoing gu this, note
ara the
following:ris ed
nte
ho eo
ut
Specified
ss a torques ra
c
ce
e
nl
Component Specified torque
pt
du
an
itte
y li
Bolts securing relay carrier 6 Nm
erm
ab
ility
ot p
wit
, is n
h re
hole
1.5 Removing and installing relay carrier
spec
es, in part or in w
and fuse holder in centre console
t to the co
The fuse box can be found in the centre beneath the dash panel.
rrectness of i
Removing
l purpos
– Disconnect batteries ⇒ page 7 .
– Remove centre console ⇒ General body repairs, interior; Rep.
nf
ercia
gr. 68 ; Assembly overview - centre console .
orm
m
atio
m
– Unscrew securing bolts -arrows- for relay carrier and fuse
o
n in
c
holder in centre console.
or
thi
te
sd
a
– Swing out relay carrier -1- together with fuse holder -2- with
iv
o
r
wires attached.
rp
cu
o
m
f
en
ng
t.
– To separate relay carrier -1- and fuse holder -2-, unscrew se‐
op
yi Co
curing bolt -3- and remove fuse holder -2-.
C py
ht. rig
rig ht
py by
Installing co Vo
by lksw
cted agen
Prote AG.
Installation is carried out in the reverse sequence of removal.
1.6 Removing and installing coupling sta‐
tion electronics box
The coupling station electronics box is removed in the course of
electronics box removal ⇒ page 305 .
1.7 Removing and installing relay carrier
and fuse holder in electronics box
The relay carrier and fuse holder in the electronics box are re‐
moved in the course of electronics box removal ⇒ page 305 .
1. Relay carriers, fuse holders, electronics boxes 311
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
2 Control units
⇒ “2.1 Overview of fitting locations - control units”, page 312
⇒ “2.2 Removing and installing onboard supply control unit J519
”, page 313
⇒ “2.3 Removing and installing data bus diagnostic interface J533
”, page 314
⇒ “2.4 Removing and installing special vehicle control unit J608
”, page 314
⇒ “2.5 Coding special vehicle control unit”, page 316
⇒ “2.6 Removing and installing rear lid power opening control unit
J938 ”, page 316
2.1 Overview of fitting locations - control units
AG. Volkswagen AG d
1 - Rear lid power opening con‐ agen oes
olksw not
trol unit - J938- d by V gu
ara
ise nte
❑ Removing and installing thor eo
⇒ page 316 ss au ra
c
ce
le
2 - Trailer detector control unit
un
pt
an
- J345-
d
itte
y li
rm
ab
❑ Installed in seat box on
pe
ility
right
ot
wit
, is n
❑ Removing and installing
h re
hole
⇒ page 219
spec
es, in part or in w
3 - Special vehicle control unit
t to the co
- J608-
❑ Installed in seat box on
right
rrectness of i
❑ Removing and installing
l purpos
⇒ page 314
4 - Dash panel insert - KX2-
nform
ercia
❑ With control unit in dash
m
a
panel insert - J285- .
com
❑ With immobiliser control tion in
r
te o
thi
unit - J362-
s
iva
do
r
❑ Removing and installing
rp
cum
fo
dash panel insert
en
ng
t.
yi
⇒ page 50 .
Co
Cop py
t. rig
5 - Onboard supply control unit
gh ht
pyri by
- J519-
co Vo
by lksw
cted agen
Prote
❑ With integrated data bus
AG.
diagnostic interface -
J533-
❑ Installed in driver foot‐
well behind relay carrier
❑ Removing and installing
⇒ page 313
312 Rep. gr.97 - Wiring
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
2.2 Removing and installing onboard supply
control unit - J519-
Note
♦ The onboard supply control unit - J519- is secured in the driver
footwell behind the relay carrier.
♦ If the control unit is replaced, select the Replace function of
the respective control unit in Guided fault finding ⇒ Ve‐
hicle diagnostic tester.
Removing
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
olkswagen AG
en AG. V
– Remove driver footwell cover ⇒ General ksw body repairs, interior;es not
ag do
Vol
Rep. gr. 68 ; Centre console;eRemoving
db
y and installing centre gu
ara
console trim in front footwell
ho
r is. nte
e t or
au ac
– Remove dash panel end ss cover on left side ⇒ General body
repairs, interior; Rep. gr. 70 ; Dash panel; Removing and in‐
ce
le
un
pt
stalling dash panel end cover .
an
d
itte
y li
erm
ab
– Release and separate electrical connectors -3- and -4-.
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
– To separate electrical connectors -3- and -4-, push locking
om
detent -1-, swing retaining clip -arrow- and pull off connector.
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Control units 313
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Release bottom fasteners -arrows- and remove onboard sup‐
ply control unit - J519- -4- downwards out of relay carrier -1-.
Installing
Install in the reverse order of removal, observing the following:
– First insert onboard supply control unit - J519- -4- in mountings
-1- and then engage securely underneath -arrows-.
agen
AG. Volkswagen AG d
oe w s no
olks t gu
byV ara
ed nte
ris
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2.3 Removing and installing data bus diag‐
nostic interface - J533-
rrectness of i
The data bus diagnostic interface - J533- is integrated into the
l purpos
onboard supply control unit - J519- . If control unit is defective,
onboard supply control unit must be renewed.
nform
ercia
– Removing and installing onboard supply control unit
⇒ page 313 .
m
a
com
tion in
2.4 Removing and installing special vehicle
r
te o
thi
control unit - J608-
s
iva
do
r
rp
cum
fo
The special vehicle control unit - J608- controls special equipment
en
ng
t.
and functions for the following special vehicles:
yi Co
Cop py
t. rig
♦ Taxis
gh ht
pyri by
Vo
co lksw
by
♦ Driving schools cted agen
Prote AG.
♦ Disabled
♦ Driving schools for the disabled
♦ Special signal vehicles
♦ Special protection vehicles
314 Rep. gr.97 - Wiring
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
♦ The special vehicle control unit - J608- is installed in the seat
wit
, is n
box of the right seat. There are 2 versions:
h re
hole
spec
♦ Special vehicle control unit - J608- -arrow- in vehicles with in‐
es, in part or in w
dividual seat on right.
t to the co
♦ Special vehicle control unit - J608- -arrow- in vehicles with
double bench seat on right.
rrectness of i
l purpos
Fault detection and fault display
The special vehicle control unit - J608- is equipped with self-di‐
nf
ercia
agnosis, which makes fault finding easier.
orm
m
atio
For fault finding, use the systems described in chapter “Vehicle
om
diagnosis, testing and information system” in “Guided Fault Find‐
n in
or c
ing” mode ⇒ Vehicle diagnostic tester.
thi
te
sd
iva
Removing
o
r
rp
cu
o
m
f
en
ng
– Switch off ignition and all electrical equipment and then re‐
t.
yi Co
move ignition key. Cop py
t. rig
gh ht
yri
Only vehicles with individual seat p by
o Vo
by c lksw
cted agen
– Disconnect vehicle battery ⇒ page 7 . Prote AG.
– Move right seat to foremost position.
– Press retaining clips -A-, move special vehicle control unit -
J608- in direction of arrow -B- and remove it from retainers
-C-.
– Release and disconnect connector on special vehicle control
unit - J608- .
Only vehicles with double bench seat
– Disconnect vehicle battery ⇒ page 7 .
– Fold up seat cushions of double bench seat.
2. Control units 315
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
– Press retaining clips -A-, move special vehicle control unit -
J608- in direction of arrow -B- and remove special vehicle
control unit - J608- from retainers -C-.
– Separate electrical connector from special vehicle control unit
- J608- .
Installing
Install in reverse order of removal.
AG. Volkswagen AG d
agen oes
ksw
2.5 Coding special vehicle control unit
ol not
byV gu
ara
ed
ris nte
For coding, use systems aut described in chapter “Vehicle diagnosis,
ho eo
ra
testing and information
s system” in “Guided Fault Finding” mode
s c
⇒ Vehicle diagnostic tester.
ce
le
un
pt
an
d
itte
2.6 Removing and installing rear lid power
y li
erm
ab
opening control unit - J938-
ility
ot p
wit
is n
h re
ole,
spec
Note
urposes, in part or in wh
t to the co
If rear lid power opening control unit - J938- is renewed, perform
adaptation routines using ⇒ Vehicle diagnostic tester.
rrectne
Removing ss
Vehicles with heater and air conditioning unit at rear
o
cial p
f in
– Remove rear heater and air conditioning unit ⇒ Heating, air
form
mer
conditioning; Rep. gr. 87 ; Rear heater and air conditioning
atio
unit; Removing and installing heater and air conditioning unit .
om
n
c
i
or
Continued for all vehicles
thi
te
sd
va
– Remove right side panel trim ⇒ General body repairs, interior;
i
o
pr
cum
r
Rep. gr. 70 ; Luggage compartment trim; Removing and in‐
fo
en
ng
stalling luggage compartment side trim .
t.
yi Co
Cop py
. rig
– Remove rear lid power opening control unit - J938- -1- from
ht ht
rig by
py
bracket -3-. co Vo
by lksw
cted agen
Prote
– Disconnect electrical connectors -2-.
AG.
Installing
Install in reverse order of removal.
316 Rep. gr.97 - Wiring
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
3 Connectors
⇒ “3.1 Repairing electrical wiring harnesses and plug-in connec‐
tions”, page 317
3.1 Repairing electrical wiring harnesses
and plug-in connections
⇒ “3.1.1 Repairs to electrical wiring harnesses”, page 317
⇒ “3.1.2 Repairing connector housings and connectors”,
page 317
3.1.1 Repairs to electrical wiring harnesses
Note
All instructions and information about this chapter: ⇒ Electrical
system; General information; Rep. gr. 97 ; Wiring harness and
connector repair; Repair of wiring harnesses .
3.1.2 Repairing connector housings and con‐
nectors
n AG. Volkswagen AG do
Note lkswage es n
ot g
o
byV ua
ed ran
All instructions and information
horis
about this chapter: ⇒ Electrical tee
system; General information;
s aut
Rep. gr. 97 ; Wiring harness and or
ac
connector repair; Repair of connector housings .
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Connectors 317
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
4 Releasing and dismantling connector
housings
Note
All instructions and information about this chapter: ⇒ Electrical
system; General information; Rep. gr. 97 ; Wiring harness and
connector repair; Releasing and dismantling connector housings .
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
318 Rep. gr.97 - Wiring
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
5 Repairing aerial wires
Note
All instructions and information about this chapter: ⇒ Electrical
system; General information; Rep. gr. 97 ; Wiring harness and
connector repair; Repair of aerial wires .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
5. Repairing aerial wires 319
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
6 Fibre optic cables
AG. Volkswagen AG d
agen oes
lksw not
Note d by
Vo gu
ara
ise nte
or eo
h
All instructions and information
s aut about this chapter: ⇒ Electrical ra
c
system; General information;
s Rep. gr. 97 ; Wiring harness and
ce
e
connector repair; Repair of fibre optic cables .
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
320 Rep. gr.97 - Wiring
California 2016 ➤ , Caravelle 2016 ➤ , Multivan 2016 ➤ , Transporter 20 ...
Electrical system - Edition 04.2019
7 Vehicle diagnosis, testing and infor‐
mation systems
Note
All instructions and information about this chapter: ⇒ Electrical
system; General information; Rep. gr. 97 ; Vehicle diagnostic,
testing and information systems .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Vehicle diagnosis, testing and information systems 321
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