K0050367120-Electrical System

Service
Workshop Manual
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Service Department. Technical Information
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Edition 10.2014
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Electrical system
Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
27 - Starter, current supply, CCS
90 - Gauges, instruments
92 - Windscreen wash/wipe system
94 - Lights, bulbs, switches - exterior
96 - Lights, bulbs, switches - interior
97 - Wiring
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AG. Volkswagen AG d
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright 2014 Volkswagen AG, Wolfsburg
K0050367120
Caddy 2004 , Caddy 2011

Electrical system - Edition 10.2014
Contents
27 - Starter, current supply, CCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
General description - battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
Assembly overview - battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
Disconnecting and reconnecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Removing and installing battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Starter . . . . . . . n. A. G. ..V.o.lk.sw. a. g.e.n.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Gd
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AssemblyVooverview
- starter . . . . .o.es. n.o.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Removing
and installing starter . . . . . . . . a.ra.n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Checking
starter . . . . . . . . . . . . . . . . . . . . . .e.or. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
ut
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ssAlternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Assembly overview - alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Removing and installing alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Checking alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Repairing alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Checking poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Start/Stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
General description - Start/Stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Removing and installing start-stop mode switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Removing and installing voltage stabiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Removing and installing battery monitoring control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
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1
1.1
1.2
1.3
1.4
1.5
1.6
2
2.1
2.2
2.3
3
3.1
3.2
3.3
3.4
3.5
4
5
5.1
5.2
5.3
5.4
90 - Gauges, instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General description - dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector pin assignment - dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning lamp symbols in dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coding dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing treble horn and bass horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking treble horn and bass horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
1.3
1.4
1.5
1.6
2
2.1
2.2
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92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
2
2.1
2.2
Windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Moving wipers to service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deactivating APP function of wiper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing wiper arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing wiper frame with linkage and wiper motor . . . . . . . . . . . . . . . . . .
Removing and installing wiper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing wiper blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing windscreen wiper rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting windscreen wiper park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing rain and light sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coding rain and light sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing washer fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
106
106
106
107
108
110
111
112
113
114
117
118
118
120
Contents

Removing and installing filler pipe for washer fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing windscreen and rear window washer pump V59 . . . . . . . . . . . .
Removing and installing windscreen washer fluid level sender G33 . . . . . . . . . . . . . . . . . .
Removing and installing windscreen spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting windscreen washer system spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear window wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - rear window wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing rear window wiper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing rear window wiper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting rear window wiper park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing rear window wiper blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing rear window wiper rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing rear window spray jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting spray jet for rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General description - headlightnwasher
system
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Assembly overview - headlight
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Removing and installing
headlight
washer
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Removing and
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Removing and
Adjusting headlight washer system spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer fluid line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.3
2.4
2.5
2.6
2.7
3
3.1
3.2
3.3
3.4
3.5
3.6
4
4.1
4.2
4.3
5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
6
7
123
123
125
127
127
129
129
131
133
135
136
137
140
140
144
144
145
145
146
147
148
151
152
153
154
155
94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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Contents
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1.21
1.22
1.23
1.24
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1.15
1.16
1.17
1.18
1.19
1.20
Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting headlight installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing front turn signal bulb M5 / M7 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing bulb for daytime running light and side light . . . . . . . . . . . . . . . .
Removing and installing daytime running light and main beam bulb . . . . . . . . . . . . . . . . . .
Removing and installing side light bulb M1 / M3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing main beam and dipped beam bulb . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing dipped beam bulb M29 / M31 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing main beam bulb M30 / M32 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing bulb for static cornering light M51/M52 . . . . . . . . . . . . . . . . . . . .
Removing and installing gas discharge lamp L13 / L14 . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing LED modules for daytime running light and side light L176 / L177
........................................................................
Removing and installing dynamic cornering light control motor V318 / V319 . . . . . . . . . .
Removing and installing swivel module position sensor G475 / G474 . . . . . . . . . . . . . . . .
Removing and installing dipped beam screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing gas discharge lamp control unit J343 / J344 . . . . . . . . . . . . . . . .
Removing and installing output module for headlight J667 / J668 . . . . . . . . . . . . . . . . . .
Removing and installing control unit for daytime running light and side light J860 / J861
........................................................................
Removing and installing cornering light and headlight range control unit J745 . . . . . . . .
Coding cornering light and headlight range control unit J745 . . . . . . . . . . . . . . . . . . . . . .
Headlight conversion for left-hand/right-hand traffic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing headlight range control actuator V48 / V49 . . . . . . . . . . . . . . . .
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1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
157
158
166
174
175
180
185
187
188
191
193
196
198
200
202
202
203
203
203
205
207
208
209
210
225

Removing and installing front left vehicle level sender G78 . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing rear left vehicle level sender G76 : . . . . . . . . . . . . . . . . . . . . . . . .
Installing repair kit for headlight housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fog light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side turn signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing side turn signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing turn signal light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tail lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - tail light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing tail light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing tail light bulb carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional brake light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing additional brake light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing additional brake light bulb/LEDs . . . . . . . . . . . . . . . . . . . . . . . . . .
Number plate light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing number plate light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing bulb for number plate light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering column switch module, vehicles up to model year 2010 . . . . . . . . . . . . . . . . . . . .
General description - steering column switch module, vehicles up to model year 2010 . .
Assembly overview - steering column switch module, vehicles up to model year 2010 . .
Components of steering column switch module - removal and installation sequence . . . .
Removing and installing steering column electronics
control unit J527 . . . . . . . . . . . . . .
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Removing and installing coil connector F350
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Removing and installing steering angle
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Removing and installing turn signal
tho switch E2 . . . . . . . . . . . . . . . . . . . . . . . .e .or. . . . . . . . .
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Removing and installing windscreen
wiper switch E . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . .
ss
Removing and installing steering column switch module base . . . . . . . . . . . . . . . . . . . . . .
Coding steering column electronics control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering column electronics control unit - final control diagnosis . . . . . . . . . . . . . . . . . . . .
Basic setting of steering angle sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering column switch module, vehicles as of model year 2011 . . . . . . . . . . . . . . . . . . . .
General description - steering column switch module, vehicles as of model year 2011 . .
Assembly overview - steering column switch module, vehicles as of model year 2011 . . . .
Components of steering column switch module - removal and installation sequence . . . .
Removing and installing steering column electronics control unit J527 . . . . . . . . . . . . . .
Steering column combination switch E595 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering column switch module base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coding steering column electronics control unit J527 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear parking aid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General description - rear parking aid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - rear parking aid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing rear parking aid control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adapting rear parking aid control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing rear parking aid senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing parking aid system warning buzzer . . . . . . . . . . . . . . . . . . . . . . . .
Park assist steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General description - park assist steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - park assist steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing parking aid control unit J446 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coding parking aid control unit J446 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adapting parking aid control unit J446 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
228
229
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253
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260
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1.25
1.26
1.27
2
2.1
2.2
2.3
3
3.1
3.2
4
4.1
4.2
4.3
5
5.1
5.2
6
6.1
6.2
7
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
7.12
8
8.1
8.2
8.3
8.4
8.5
8.6
8.7
9
9.1
9.2
9.3
9.4
9.5
9.6
10
10.1
10.2
10.3
10.4
10.5
Contents
iii

Removing and installing front parking aid senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing rear parking aid senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing front park assist steering sender . . . . . . . . . . . . . . . . . . . . . . . . . .
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Removing and installing rear park assist
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Renewing parking aid sender orbypark
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Renewing retainers for parking
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ris aid senders and park assist steering senders
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Removing and installings apark assist steering button E581 . . . . . . . . . .o.r a.c . . . . . . . . . . . .
s
Removing and installing parking aid button E266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing front parking aid warning buzzer . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing rear parking aid warning buzzer . . . . . . . . . . . . . . . . . . . . . . . . . .
Adapting parking aid warning buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General description - towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing trailer socket U10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin assignment of trailer socket U10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing trailer detector control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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10.6
10.7
10.8
10.9
10.10
10.11
10.12
10.13
10.14
10.15
10.16
11
11.1
11.2
11.3
11.4
295
297
300
303
305
306
310
311
311
312
312
314
314
314
317
318
96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
Contents
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6.4
6.5
6.6
6.7
6.8
6.9
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3
3.1
3.2
3.3
4
4.1
5
5.1
5.2
5.3
5.4
5.5
5.6
6
6.1
6.2
6.3
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2.1
2.2
2.3
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1.3
1.4
1.5
Lights and controls in the dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing headlight range control regulator and switch and instrument
illumination regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing front passenger side airbag deactivated warning lamp . . . . . . . .
Removing and installing hazard warning light switch E229 . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing key operated switch to deactivate front passenger front airbag
........................................................................
Lights and controls in front doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing front left window regulator switch . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing front right window regulator switch . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing switch for exterior mirror adjustment and button for central locking,
driver side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing door contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lights and controls in sliding doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing contact strip in left sliding door . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing contact strip in right sliding door . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing rear door contact switches for sliding door or side door . . . . . . . .
Lights and controls in the centre console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing buttons in centre console storage compartment . . . . . . . . . . . . . .
Lights and controls in luggage compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing luggage compartment light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing bulb for luggage compartment light . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing luggage compartment light switch F5 . . . . . . . . . . . . . . . . . . . . . .
Removing and installing central locking switch in left wing door F213 . . . . . . . . . . . . . . . .
Removing and installing rear door contact switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing rear lid release switch E165 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lights and controls in the roof trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing front interior light , vehicles as of 06.07 . . . . . . . . . . . . . . . . . . . .
Removing and installing bulb for front interior light , vehicles as of 06.07 . . . . . . . . . . . . . .
Removing and installing front interior light , driver side reading light and front passenger
reading light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing bulb for front interior light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing bulb for front reading light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing left centre reading lamp and right centre reading lamp . . . . . . . .
Removing and installing rear left interior light and rear right interior light . . . . . . . . . . . . . .
Removing and installing bulbs for centre reading lights and rear interior lights . . . . . . . .
Removing and installing vanity mirror light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.1
1.2
320
320
321
322
323
324
325
325
326
327
327
328
328
330
330
332
332
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334
335
336
336
336
336
337
337
338
338
340
341
342
342
343
344

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Removing and installing light for vanity mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lights and controls in engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing bonnet contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other interior lights and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing interior monitoring deactivation switch and deactivation button for
vehicle inclination sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Cigarette lighter and 12 V socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1
Removing and installing cigarette lighter U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2
Removing and installing 12 V socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Immobiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1 General description - immobiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2 Removing and installing immobiliser control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3 Removing and installing immobiliser reader coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4 Removing and installing ignition key variable code transponder . . . . . . . . . . . . . . . . . . . .
10.5 Adapting ignition keys to the immobiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.6 Adapting ignition keys to the convenience system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Anti-theft alarm (ATA)
......................................................
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11.2 ed bRemoving
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deactivation switch and deactivation button for
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11.3
Removing and installing interior monitoring
ss
11.4 Removing and installing vehicle inclination sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.5 Removing and installing central locking and anti-theft alarm system aerial . . . . . . . . . . . .
11.6 Removing and installing alarm horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.7 Reading alarm sources of anti-theft alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Ignition/starter switch and lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.1 Removing and installing ignition/starter switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.2 Checking ignition/starter switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.3 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.4 Removing and installing steering lock housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.5 Removing and installing ignition key withdrawal lock solenoid . . . . . . . . . . . . . . . . . . . . . .
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6.10
7
7.1
8
8.1
345
346
346
347
347
349
349
349
351
351
351
351
352
352
352
354
354
355
355
356
356
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357
359
359
361
362
366
367
97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Relay carriers, fuse holders, E-boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview of fitting locations - relay carriers, fuse holders, E-boxes . . . . . . . . . . . . . . . . . .
Removing and installing fuse holder on left beneath dash panel . . . . . . . . . . . . . . . . . . . .
Removing and installing relay carrier on left of dash panel . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing relay carrier on onboard supply control unit . . . . . . . . . . . . . . . .
Removing and installing E-box on left side of engine compartment . . . . . . . . . . . . . . . . . .
Control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing onboard supply control unit , vehicles up to model year 2010 . .
Removing and installing onboard supply control unit , vehicles as of model year 2011 . .
Removing and installing data bus diagnostic interface . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing convenience system central control unit . . . . . . . . . . . . . . . . . .
Removing and installing special vehicle control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairing electrical wiring harnesses and plug-in connections . . . . . . . . . . . . . . . . . . . . . .
Renewing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle diagnosis, testing and information systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.1
1.2
1.3
1.4
1.5
2
2.1
2.2
2.3
2.4
2.5
3
3.1
4
5
Contents
369
369
370
370
371
374
379
379
382
387
389
392
401
401
402
403
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27
Starter, current supply, CCS
Battery
(VRL007279; Edition 10.2014)

1.1 General description - battery, page 1
1.2 Assembly overview - battery, page 1
1.3 Disconnecting and reconnecting battery, page 3
1.4 Removing and installing battery, page 6
1.5 Checking battery, page 11
1.6 Charging battery, page 11
1.1
General description - battery
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Assembly overview - battery
ility
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1.2
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ss
1.2.1 Assembly overview - vehicles without battery monitor

control unit J367 , page 1
1.2.1
rrectness of i
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wit
1.2.2 Assembly overview - vehicles with battery monitor control

unit J367 , page 2
Assembly overview - vehicles without

battery monitor control unit - J367-
Warning notices and safety regulations
All the instructions and information regarding this manual are

available in the workshop manual Electrical system, General in
formation Electrical system, General information; Rep. gr. 27 ;
Battery; Warning notices and safety regulations .
Battery terminal connection
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Battery; Battery terminal connection .
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1 - Earth wire battery terminal
clamp
Comply with the instruc
tions regarding threa
ded connections of the
battery terminals
page 1 .
2 - Securing nut for earth wire
battery terminal clamp
M6
6 Nm
3 - Positive wire battery termi
nal clamp
battery terminals
page 1 .
4 - Securing nut for positive
wire battery terminal clamp
M6
6 Nm
5 - Battery
page 6 .
rrectness of i
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at
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7 - Clamping plate securing nut

M8 x 35
20 Nm
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6 - Clamping plate
Assembly overview - vehicles with bat

tery monitor control unit - J367-
Warning notices and safety regulations

Battery; Warning notices and safety regulations .
Battery terminal connection
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Rep. gr.27 - Starter, current supply, CCS
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Battery; Battery terminal connection .
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4 - Securing nut for positive

wire battery terminal clamp
M6
6 Nm
ht
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3 - Positive wire battery termi

nal clamp
battery terminals
page 2 .
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2 - Securing nut for earth wire

battery terminal clamp
M6
6 Nm
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1 - Battery earth terminal with

integrated battery monitor con
trol unit - J367 Battery monitor control
unit - J367- only in vehi
cles with Start/Stop sys
tem.
battery terminals
page 2 .
Comply with instruc
tions regarding battery
monitoring control unit J367- (battery sensor)
page 95 .
un
le

5 - Battery
page 6 .
Parametering battery after replacement page 11
6 - Battery carrier
7 - Clamping plate
8 - Clamping plate securing nut
M8 x 35
20 Nm
1.3
Disconnecting and reconnecting battery

WARNING
Danger of injury! Comply with the warning notices and safety

regulations page 1 !
1. Battery

Note
The order in which the work steps is carried out should be
followed carefully.
Disconnecting the battery earth strap (open circuit) provides a
safe working environment for repairs to the electrical system.
The battery positive wire need only be disconnected for re
moval of the battery.
Special tools and workshop equipment required
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Disconnecting battery:
Switch off ignition and all electrical loads, and pull out ignition
key.
Only for vehicles with battery housing:
Open locking device -arrow- and remove battery housing cov
er.
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Open cover -1- of battery protective jacket.

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Only for vehicles with battery protective jacket:
In new vehicles, the battery box has been discontinued. Heat in

sulation has been fitted around the battery instead.
Continuation for all vehicles:
rrectne
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spec
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Torque wrench - V.A.G 1331-

Loosen securing nut -1- and disconnect battery earth cable
from battery negative terminal.
Then, loosen securing nut -2- and disconnect battery positive
cable from battery positive terminal.
Connecting battery:
Caution
Battery terminal clamps must be fitted only by hand without

force to prevent damage to battery housing.
Battery terminals must not be greased.
Fit positive cable clamp -2- onto battery positive terminal and
tighten securing nut to 6 Nm.
Fit earth cable clamp -1- onto battery negative terminal and
tighten securing nut to 6 Nm.
Fit cover for battery housing and lock it in position or close
battery protective jacket.
Work through steps listed in table.
Procedure
Performed
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Read event memory: ss au
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atio
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Guided fault finding with vehicle diag

nostic tester
Steering angle sender - carry out zero
compensation:
Guided fault finding with vehicle diag
nostic tester
Clock:
Check clock setting, adjust if necessary.
Electric window regulators:
Fully open and then close all windows.
Functional check:
All electrical consumers
Chart can be printed out as required.
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1. Battery
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1.4
Removing and installing battery
1.4.1 Removing and installing battery, vehicles with petrol en

gine, page 6
1.4.2 Removing and installing battery, vehicles with diesel en
gine, page 8
wagen AG
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1.4.3 Parameterising battery after replacement,
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Start/Stop system, page 11
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Removing and installing battery, vehi

cles with petrol engine
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1.4.1
ed
ris
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ss
Replacing battery on vehicles with Start/Stop system:
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
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in t
his
Because of its higher deep-cycle resistance, only an absorbent

glass mat battery is used as a starter battery instead of the normal
lead battery in vehicles with Start/Stop system.
In case of repair, note correct part number designation in ETKA.
The modified components for the Start/Stop system have no spe
cial markings. They do not differ externally, or hardly, from stand
ard components.
Note
In vehicles with a battery sensor (start-stop system), the bat
tery has to be parameterised after a new starter battery has

been installed.
The battery parameterisation sends the technical data of the

Performing battery parameterisation page 11 .
Prote
cted
by
To disconnect and reconnect the battery, the procedure de

scribed in the workshop manual should be strictly adhered to
page 3 .
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WARNING
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new battery to the battery monitor.

Spring-type clip pliers - VAS 5024A-
un
le
On vehicles with rear wing doors only:

Pull out dipstick.
Remove engine cover panel.
Disconnect battery page 3 .
Loosen spring-type clip -1-, pull off vacuum hose -2- and undo
bolt -3- of air filter housing.
Pull suction hose off air filter housing.
Prote
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Pull wall of battery box upwards in direction of arrow.
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Pull air filter housing upwards out of the brackets and remove.
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form
spec
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Removing battery:
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Unscrew securing bolt -1- and remove clamping plate -2-.
1. Battery
ility
ab
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Installing battery
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itte
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Fold grips -arrows- upwards and remove battery.
rrectness of i
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spec
a
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Caution
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Install in the reverse order of removal. When doing this, note the
following:
A loosely fitted battery creates the following dangers:

Shortened service life due to damage from vibration (dan
ger of explosion)
The cells in the battery will be damaged if the battery is
not secured correctly.
Prote
cted
by
1.4.2
Removing and installing battery, vehi

cles with diesel engine

ard components.
Note
In vehicles with a battery sensor (start-stop system), the bat
tery has to be parameterised after a new starter battery has

been installed.
The battery parameterisation sends the technical data of the
new battery to the battery monitor.
Performing battery parameterisation page 11 .

WARNING

AG.
On vehicles with start-stop system, the procedure parameteris

ing battery after replacement has to be performed after the
battery is replaced to ensure that the start-stop system subse
quently works properly page 11 .
agen
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Connecting battery page 3 .
c
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After installing battery, check it is firmly seated.
ht
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Tighten bolt for securing battery clamping plate to 20 Nm.
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Poor crash safety.
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Damage to battery housing by securing bracket (possibil

ity of acid leaking, with high consequential costs)

Caution

page 3 .
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Removing battery:
On vehicles with rear wing doors only:
Pull out dipstick.
Pull engine cover panel upwards -arrows A- and forwards
-arrow B-.
ht
rig
py
Co
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form
spec
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Spring-type clip pliers - VAS 5024A-
1. Battery
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Loosen spring-type clip -1-, pull off vacuum hose -2- and undoby V
ara
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bolt -3- of air filter housing.
is
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a
Pull suction hose off air filter housing.
c
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Pull wall of battery box upwards in direction of arrow.

Note
AG.
10
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Unscrew securing bolt -1- and remove clamping plate -2-.
ht
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spec
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Fold grips -arrows- upwards and remove battery.
Installing battery
following:
Caution
A loosely fitted battery creates the following dangers:

Shortened service life due to damage from vibration (dan
ger of explosion)
The cells in the battery will be damaged if the battery is
not secured correctly.
Damage to battery housing by securing bracket (possibil
ity of acid leaking, with high consequential costs)
Poor crash safety.
Tighten bolt for securing battery clamping plate to 20 Nm.
After installing battery, check it is firmly seated.
1.4.3
Parameterising battery after replace

ment, vehicles with Start/Stop system
n AG. Volkswagen AG
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Connect vehicle diagnostic
not Gen
olks tester Electrical system,
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eral information; Rep.
b
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information systems;
Connecting
vehicle
diagnostic
tester
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Using GoTo button, select Functions/component and then

the following menu options in succession:
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Electrical system
01 - On Board Diagnostic capable systems
Battery monitoring
Battery monitoring function
Parametering battery after replacement
1.5
Checking battery
Charging battery
General information for checking batteries is available in the

workshop manual Electrical system, General information
Electrical system, General information; Rep. gr. 27 ; Checking
battery .
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1.6
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General information for checking batteries is available in the

workshop manual Electrical system, General information
Electrical system, General information; Rep. gr. 27 ; Checking
battery .
rrectness of i
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nform
spec
a
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Body
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Select Guided
fault finding in vehicle diagnostic tester .
ss
1. Battery
11
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Starter
2.1 Assembly overview - starter, page 12

2.2 Removing and installing starter, page 13
2.3 Checking starter , page 42
2.1
Assembly overview - starter
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1 - Starter
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Checking page 42 . ise
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Earth cable to starteraut
ra
c
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bolt: 20 Nm.
Wiring retainer to starter
securing bolt: 15 Nm.
rrectness of i
t to the co
nf
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spec
atio
h re
n in
wit
2 - Battery positive wire con

nection to starter
3 - Battery positive wire secur
ing nut to starter
M8
20 Nm
4 - Protective cap
5 - Starter securing bolts

M10 = 60 Nm
M12 = 75 Nm
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12
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Air filter housing to body: 10 Nm.

2.2
Removing and installing starter
2.2.1 Removing and installing starter, 1.2 l injection engine,

manual gearbox, page 13
2.2.4 Removing and installing starter, 2.0 l SDI engine, manual
gearbox, page 20
2.2.5 Removing and installing starter, 1.6 l TDI engine, manual
gearbox, page 24
gearbox, page 28
gearbox, page 32
2.2.8 Removing and installing starter, 2.0 l natural gas engine,
2.2.9 Removing and installing starter, 1.9 l TDI engine, dual
clutch gearbox, page 39
2.2.1
Removing and installing starter, 1.2 l in

jection engine, manual gearbox
Renewing starter on vehicles with Start/Stop system:

Due to the higher requirements on the starter when the Start/Stop
system is activated, e.g. in urban traffic/driving, the deep-cycle
resistance has been increased and the ring gear reinforced.
When renewing starter, make sure the new one with the correct
part designation as shown in ETKA (Electronic Parts Cata
logue) is used. Components adapted to Start/Stop system are not
identified separately and are not or barely different from normal
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or
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rrectness of i
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spec
a
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wit
thi
s
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l purpos
hole
ercia
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com
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itte
d
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page 3 .
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2. Starter
13
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Remove air filter housing Engine; Rep. gr. 24 ; Injection
system; Assembly overview - air filter .
AG.
Unscrew and remove earth wire from upper starter bolt

-arrow-.
14
agen
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Prote
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by
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rig
ht
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yi
Unbolt positive cable -1- and release and disconnect electrical

connector of terminal 50 -2-.
ht
rig
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Push protective caps off solenoid switch downwards in direc

tion of -arrow-.
rrectne
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f
i
t to the co
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form
spec
atio
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Removing:
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Undo upper starter bolt -arrow-.
If fitted, remove noise insulation General body repairs, ex
terior; Rep. gr. 66 ; Noise insulation .
es, in part or in w
l purpos
hole
ercia
, is n
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erm
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Undo nut -1- and remove it from lower securing bolt of starter.
Remove wire holder -2-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Undo lower starter bolt -arrow-.
Remove starter by taking it downwards out of the vehicle.
AG.
Prote
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by
2.2.2
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Tighten threaded connections to specified torque given in as

sembly overview page 12 .
do
c
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en
following:
ht
rig
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Co
t.
Installing:


Caution

page 3 .
2. Starter
15

Torque wrench (5 - 50 Nm) - V.A.G 1331-
es, in part or in w
l purpos
hole
ercia
, is n
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om
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at
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his
Removing:
AG.
16
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Unscrew and remove earth wire from starter bolt -arrow-.
ht
rig
py
Co
t.
Unbolt positive cable -2-.
do
c
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en
Release and disconnect connector of terminal 50 -1-.

Unscrew securing nut -1- from starter securing bolt and re

move bracket -2-.

Remove starter.
Installing:
G. Volkswagen AG d
oes
not
gu
ara
nte
eo
in as
ra
c
A
agen
Install in the reverse order of removal. When doing lthis,
ksw note the
o
V
following:
by
ed
ris


agen
lksw
Vo
by

page 3 .
ht
rig
py
Co
t.
Caution
r
fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
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um
en
2.2.3
ole,
cial p
is n
mer
m
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erm
or
e
t
a
itte
v
i
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p
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ility
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Tighten threaded connections to specified

tho torque given
au
s
s
2. Starter
17
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi

Special tools and workshop
equipment required
Torque wrench - V.A.G
1331 Torque wrench - V.A.G
1332-
AG. Volkswagen AG d
agen
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not
l
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rrectness of i
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t
i
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o
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wit
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s
Removing:
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
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pt
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un
le
Spring-type clip pliers VAS 5024-
Loosen spring-type clip -1- using spring-type clip pliers - VAS

5024- and undo and remove bolt -2-.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
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gh
t.
C
op
yi
ht
rig
py
Co
t.
18
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Release hose -3- and pull off air filter housing.

Pull air filter housing upwards on right-hand side out of rubber
mounting -arrow-.
Remove air filter housing from vehicle.
Push protective cap off solenoid switch downwards in direction

of -arrow-.

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
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not
l
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V
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b
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d
nte
ise
r
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t
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ra
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c
s
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rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
thi
sd
o
cu
m
en
2. Starter
19
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
olkswagen AG
en AG. V
does
not
gu
ara
nte
eo
ra
c
-arrow-.
wag
Caddy 2004V
olks, Caddy 2011
y
b
d system - Edition 10.2014
Electrical
se
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
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g
n
bolt
ility
ab
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an
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ce
Undo
ri
ho
ut
a
upper
starter
ss

do
c
um
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi

Remove starter.
Installing:
following:
2.2.4
Removing and installing starter, 2.0 l

SDI engine, manual gearbox

Caution

page 3 .
20
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

un
le

1332-
ht
rig
py
Co
t.
r
fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
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o
c
erm
or
e
t
a
itte
v
i
r
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p
1331-
ility
ab
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an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
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V
gu
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b
ara
d
nte
equipment requiredorise
eo
h
t
u
ra
a
c
s
Torque wrench
V.A.G
s
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Removing:
-arrow B-.
2. Starter
21

5024- .
Release and disconnect electrical connector -2-.
Remove securing bolt -3-.
ility
ab
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an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
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V
gu
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b
ara
d
nte
ise
r
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h
t
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ra
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rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
Pull off vacuum hose -arrow-.
Pull air filter housing upwards on right-hand side out of rubber

mounting -arrow-.
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
AG.
Prote
cted
by
ht
rig
py
Co
t.
22
thi
sd
o
cu
m
en

of -arrow-.

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
es n
wage
s
k
l
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ua
b
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ran
ir se
tee
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t
or
u
ac
a
ss
ht
rig
py
Co
t.

thi
sd
o
cu
m
en
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
2. Starter
23

Remove starter.
Installing:
following:
2.2.5

TDI engine, manual gearbox

Caution
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
do
c
um
en
24
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
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b
ara
d
e
To disconnect and reconnectristhe battery, the procedure de
nte
o
eo
h
scribed in the workshop manual
should be strictly adhered to
ut
ra
a
c
s
page 3 .
s

equipment required
1332 Spring-type clip pliers VAS 5024-
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Removing:
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
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V
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b
ara
d
nte
ise
r
o
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h
t
u
ra
a
c
s
s
ht
rig
py
Co
t.

5024- and pull vacuum hose -3- off.
do
c
um
en
2. Starter
25
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi

Unscrew securing bolt -arrowof air filter housing.
Release locking lug -arrow- and remove cover.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Pull hose -arrow- off air filter housing and remove.

Pull air filter housing upwards out of its rubber mountings and
remove from vehicle.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
ht
rig
py
Co
t.
26
do
c
um
en

of -arrow-.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Undo nut -arrowof upper bolt securing the starter and remove
earth wire.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce

thi
sd
o
cu
m
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi

Undo nut -1- and remove it from lower bolt securing the starter.
2. Starter
27

Installing:
following:
2.2.6


Caution

scribed in the workshop manual should be strictlyoladhered
to
. V kswagen AG
page 3 .
gen AG
does
a
w
s
not
gu
ara
nte
eo
ra
c
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
thi
sd
o
cu
m
en
28
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
k
Vol
by
d
e
ris
tho
u
a
ss

equipment required
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
thi
sd
o
cu
m
en
AG.
Prote
cted
by
agen
lksw
Vo
by

1332-
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
ht
rig
py
Co
t.

1331-
c
o
p
yri
gh
t
.
C
op
yi
Removing:
-arrow B-.
2. Starter
29

ility
ab
y li
an
pt
ce
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
un
le
Loosen spring-type clip -2- using spring-type clip

5024- .
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
pliers - VAS d by V
ara
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
30
AG.
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
ht
rig
py
Co
t.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Pull vacuum hose -arrow- off air filter housing.

of -arrow-.

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ss
oes
not
gu
ara
nte
eo
ra
c
ksw
Vol
by
d
e
ris
ho
t
au
ility
ab
y li
an
pt
ce
un
le
Unscrew and remove earth wire from starter bolt

-arrow-.
AG. Volkswagen AG d
agen
do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n

2. Starter
31
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi


Remove starter.
Installing:
following:
2.2.7
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s

Caution

page 3 .
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
ht
rig
py
Co
t.
32
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

ility
ab
y li
an
pt
ce

equipment required
1332-
pe
rm
itte
d
Removing:
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
ility
ab
y li
an
pt
ce
un
le
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n

5024- .
2. Starter
33
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi

Pull vacuum hose -arrow- off air filter housing.
ility
ab
y li
an
pt
ce
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
t
Pull air filter housing upwards out of theaubrackets
and remove.
ra
c
s
s

of -arrow-.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
do
c
um
en
34

AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
Unscrew and remove earth wire from bolt securing the starter
-arrow-.

ht
rig
py
Co
t.
r
fo
ng
Undo securing nuts -1- and remove cable bracket -2-.
2. Starter
35
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi

Installing:
following:
2.2.8

natural gas engine, manual gearbox

AG. Volkswagen AG d
agen
oes
ksw
not
l
o
resistance has been increased and the ring geary reinforced.
V
g
ua
ran
tee
b
ed
un
le
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p

page 3 .
AG.
Prote
cted
by
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
36
ht
rig
py
Co
t.
r
fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
Caution
or
ac
ility
ab
y li
an
pt
ce
is
When renewing starter, make sure the newhorone
with the correct
t
u
part designation as shown in ETKA (Electronic
Parts Cata
a
s
logue) is used. Components adapted tosStart/Stop system are not

Removing:
5024- .
Release hose -3- and pull off air filter housing.
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
Pull air filter housing upwards on

mounting -arrow-.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
right-hand
side out of rubber
ut
ra
a
c
s
s
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

of -arrow-.
thi
sd
o
cu
m
en
2. Starter
37
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi

Unscrew and remove earth wire from bolt securing the starter
-arrow-.

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Unscrew nut -1- of lower bolt securing starter and remove wir
ing retainer -2-.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
ht
rig
py
Co
t.
38
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
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Installing:
following:
2.2.9

TDI engine, dual clutch gearbox

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Caution thoris
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2. Starter
39
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equipment required
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Pull hose -arrow- off air filter housing and remove from vehicle.
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Pull air filter housing upwards out of the brackets and remove
from vehicle.
AG.

of -arrow-.
2. Starter
41

Unclip line -1- from bracket -2-.
rrectness of i
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Remove starter by taking it upwards out of the vehicle.
Installing:
do
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2.3
Checking starter
Connect vehicle diagnostic tester Electrical system, Gen

eral information; Rep. gr. 97 ; Vehicle diagnosis, testing and
information systems; Connecting vehicle diagnostic tester .
Select Guided fault finding in vehicle diagnostic tester .
42

Body
Electrical system
27 - Starter, current supply
Electrical components
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B - Starter
43
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Alternator
3.1 Assembly overview - alternator, page 44
rrectness of i
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wit
3.2 Removing and installing alternator, page 58

3.3 Checking alternator, page 86
3.4 Repairing alternator, page 87
3.5 Checking poly V-belt, page 93
3.1
Assembly overview - alternator
3.1.1 Assembly overview - alternator, 1.2 l injection engine with

air conditioning system, page 44
3.1.2 Assembly overview - alternator, 1.4 l injection engine
without air conditioning system, page 46
3.1.3 Assembly overview - alternator, 1.4 l injection engine with
air conditioning system, page 47
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3.1.5 Assembly overview - alternator, 1.6 l diesel engine, com

mon rail (TDI), page 50
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3.1.4 Assembly overview - alternator, 1.6 l injection engine,

page 48
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Caddy 2004 , sCaddy
2011
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Electrical system
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3.1.6 Assembly overview - alternator, 1.9 l diesel engine, unit

injector (TDI), page 51
AG.
3.1.8 Assembly overview - alternator, 2.0 l diesel engine, com

mon rail (TDI), page 53
3.1.9 Assembly overview - alternator, 2.0 l diesel engine, unit
injector (SDI), page 54
3.1.10 Assembly overview - alternator, 2.0 l natural gas engine
without air conditioning system, page 55
3.1.11 Assembly overview - alternator, 2.0 l natural gas engine
with air conditioning system, page 56
3.1.1
44
Assembly overview - alternator, 1.2 l injection engine with air conditioning

system
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1 - Securing bolts of voltage

regulator
M4
2 Nm
2 - Hexagon head flange bolts

For securing protective
cap
M5
4.5 Nm
Prote
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by
8 - Voltage regulator
voltage regulator
page 87
AG.
7 - Protective cap
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4 - Hexagon flange nut

M8
15 Nm
ht
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3 - Battery positive wire
9 - Alternator
alternator page 58 .
Checking alternator
page 86 .
10 - Belt pulley
poly V-belt pulley on al
ternator page 87 .
Specified torque for poly
V-belt pulley with freewheel to alternator: 80 Nm
Specified torque for poly V-belt pulley without freewheel to alternator: 65 Nm
Checking poly V-belt page 93
M8
20 Nm
Not illustrated
Securing bolt for guide roller: M8, 40 Nm
Securing bolt for air conditioner compressor: M8, 25 Nm
3. Alternator
45

3.1.2
Assembly overview - alternator, 1.4 l injection engine without air condition

ing system

M8 x 90
20 Nm
2 - Ancillary bracket
For alternator
ole,
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voltage regulator page 87
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6 - Cross-head screws
M4 x 18
2 Nm
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4 - Alternator
Checking alternator
page 86 .
ternator page 87 .
V-belt pulley with free
wheel to alternator:
80 Nm
V-belt pulley without
freewheel to alternator:
65 Nm
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M10 x 55, Aluminium
cylinder block
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Dacromet
bolts (entire
c
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bolt sof greenish colour)
must be renewed when
carrying out repair work.
7 - Protective cap for alternator

8 - Hexagon bolts
M4 x 20
2 Nm
9 - Poly V-belt
Poly V-belt routing Power unit; Rep. gr. 13 ; Cylinder block, belt pulley end; Assembly overview - poly
V-belt .
10 - Hexagon head flange bolt
M8 x 39
25 Nm
46

11 - Tensioning spring
3.1.3
Assembly overview - alternator, 1.4 l injection engine with air conditioning

system
un
le
3 - Tensioning roller

M8 x 90
20 Nm
M10 x 55, Aluminium
cylinder block
M10 x 50, Cast iron cyl
inder block
40 Nm
Dacromet bolts (entire
bolt of greenish colour)
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M8 x 42
20 Nm
ht
rig
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For alternator and air
conditioner compressor.
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M10 x 22
60 Nm
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M10 x 45, Aluminium
cylinder block
M10 x 40, Cast iron cylinder block
40 Nm
Dacromet bolts (entire bolt of greenish colour) must be renewed when carrying out repair work.
10 - Hexagon bolts with washer
M4 x 20
2 Nm
11 - Protective cap for carbon brushes
Removing and installing voltage regulator page 87
13 - Alternator
Removing and installing alternator page 63 .
Checking alternator page 86 .
Removing and installing poly V-belt pulley on alternator page 87 .
Specified torque for poly V-belt pulley with freewheel to alternator: 80 Nm
3. Alternator
47
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Caddy 2011
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Caddy 2004 ,
15 - Hexagon bolt with washer and threaded element

M4 x 20, M4 x 15
2 Nm
16 - Poly V-belt tensioning element
3.1.4
Assembly overview - alternator, 1.6 l injection engine
Prote
cted
by

M8
6 - Cross-head screw
M5 x 21
4.5 Nm
7 - Hexagon nut, flat
M8
8 - Washer
M5
M4 x 19
2 Nm
M4 x 13
2 Nm
48
AG.
4 - Protective cap
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M8 x 45
52 Nm
Observe tightening se
quence Power unit;
Rep. gr. 13 ; Cylinder
block, belt pulley end;
ancillary bracket .
ht
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M8 x 50
23 Nm
thi
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M8 x 108
23 Nm
rrectness of i
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nf
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spec
atio
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wit
14 - Poly V-belt
V-belt .

12 - Alternator
wagen Apulley
. VolksV-belt
AGpoly
Specified torque
for
G do without freewheel to alternator: 65 Nm
agen
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13 - Poly V-belt
ara
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Checking
poly V-belt page 93
h
ut
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c
s
s Poly V-belt routing Power unit; Rep. gr. 13 ; Cylinder
block, belt pulley end; Assembly overview - poly
V-belt .
rrectness of i
t to the co
nf
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r
m
spec
atio
h re
n in
wit
For alternator and air conditioner compressor.
Observe tightening sequence Power unit; Rep. gr. 13 ; Cylinder block, belt pulley end; Removing and
installing ancillary bracket .
15 - Poly V-belt tensioning element
M8 x 90
23 Nm
thi
sd
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cu
m
en
3. Alternator
49
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3.1.5
Assembly overview - alternator, 1.6 l diesel engine, common rail (TDI)
1 - Hexagon bolt with washer

and threaded element
M4 x 20, M4 x 15
2 Nm
M4 x 20
2 Nm
4 - Protective cap for carbon
brushes
voltage regulator
page 87
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
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thi
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6 - Alternator
Checking alternator
page 86 .
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s
ternator page 87 .
k
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Specified torque for poly rised
tee
o
V-belt pulley with free uth
or
ac
a
wheel to alternator: ss
80 Nm
V-belt pulley without
freewheel to alternator:
65 Nm
7 - Poly V-belt
Checking poly V-belt
page 93
V-belt .
M8 x 90
20 Nm
Not illustrated
M8 securing bolts of air conditioner compressor on ancillary

bracket - 23 Nm
AG.
Prote
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50
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M5 securing nut on back of alternator for wiring clamp - 3.2 Nm

3.1.6
Assembly overview - alternator, 1.9 l diesel engine, unit injector (TDI)

M8 x 45
20 Nm
2 - Poly V-belt tensioning ele
ment
thi
sd
o
cu
m
en

M10 x 45
45 Nm
quence Power unit;
ancillary bracket .
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

M10 x 65
45 Nm
quence Power unit;
ancillary bracket .
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M8 x 90
20 Nm
ht
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Prote
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.
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7 - Hexagon bolt with washer and threaded element

M4 x 20, M4 x 15
2 Nm
M4 x 20
2 Nm
10 - Protective cap for carbon brushes
12 - Alternator
3. Alternator
51

13 - Poly V-belt
V-belt .
3.1.7
Assembly overview - alternator, 2.0 l diesel engine, unit injector (TDI)
1 - Hexagon bolt with washer

and threaded element
M4 x 20, M4 x 15
2 Nm
voltage regulator
page 87
Prote
cted
by
M5 securing nut on back of alternator for wiring clamp - 3.2 Nm

M8 securing bolts of air conditioner compressor on ancillary
bracket - 23 Nm
52
AG.
Not illustrated
agen
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.
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M8 x 90
20 Nm
ht
rig
py
Co
t.
7 - Poly V-belt
Poly V-belt routing
Power unit; Rep. gr. 13 ;
Cylinder block, belt pul
ley end; Assembly over
view - poly V-belt .
page 93
r
fo
ng
6 - Alternator
alternator page 75
Checking alternator
page 86
ternator page 87
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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en
ole,
cial p
is n
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or
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t
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v
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p
4 - Protective cap for carbon

brushes
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M4 x 20
2 Nm
un
le

3.1.8
Assembly overview - alternator, 2.0 l diesel engine, common rail (TDI)
1 - Poly V-belt
page 93
Poly V-belt routing
. Volkswagen AG
gen;AG
Power unit; Rep. gr.
does
wa13
s
k
not
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o
Cylinder block,
gu
y V belt pul
b
ara
d
e
ley end; Assembly
over
nte
ris
o
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view -upoly
V-belt .
th
r
a
ss
pe
rm
itte
d
un
le
ac
ility
ab
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an
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ce
2 - Hexagon bolts
20 Nm
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
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com

ment
For alternator, power
steering vane pump and
air conditioner compres
sor.
do
c
um
en
r
te o
iva
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rp
fo
g
n
5 - Hexagon bolt
45 Nm
quence Power unit;
ancillary bracket .
6 - Alternator
Checking alternator
page 86 .
ternator page 87 .
V-belt pulley with freewheel to alternator: 80 Nm
ht
rig
py
Co
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AG.
Prote
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by
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p
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.
C
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7 - Hexagon bolt
25 Nm
Not illustrated
M8 securing nut B+ wire to alternator, 15 Nm
M5 securing nut of wiring retainer on rear of alternator, 3.2 Nm
3. Alternator
53

3.1.9
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Assembly overview - alternator, 2.0 l diesel engine, unit injector (SDI)

es, in part or in w
l purpos
hole
ercia
, is n
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ot p
om
c
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erm
o
e
t
a
itte
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or
nl
f
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M8 x 45
20 Nm
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

ment

M8 x 90
20 Nm
do
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um
en
ht
rig
py
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Prote
cted
by
c
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p
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gh
t
.
C
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yi

M10 x 65
45 Nm
quence Power unit;
ancillary bracket .

M10 x 45
45 Nm
quence Power unit;
ancillary bracket .
M4 x 20
2 Nm
8 - Protective cap
10 - Alternator
11 - Poly V-belt
54

V-belt .
3.1.10
Assembly overview - alternator, 2.0 l natural gas engine without air condi
tioning system

M8 x 90
20 Nm
M8 x 50
23 Nm
ment
For alternator
5 - Hexagon nut
7 - Protective cap

Securing nut for B+ wire
on rear of alternator
M8
15 Nm
agen
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M4 x 19
2 Nm
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11 - Washer
M5
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M8
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M5 x 21
4.5 Nm
rrectne
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6 - Hexagon socket head bolts

M10 x 45
AG. Volkswagen AG d
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Rep. gr. 13 ; Cylinders aut
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block, belt pulley end;s
ancillary bracket .
M4 x 13
2 Nm
3. Alternator
55

AG. Volkswagen AG d
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Removing and installing voltage regulator
page 87
ris
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a
15 - Alternator
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16 - Poly V-belt
V-belt .
Not illustrated

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5 - Hexagon nut
6 - Hexagon socket head bolts
M10 x 45
45 Nm
quence Power unit;
ancillary bracket .
7 - Protective cap
Securing nut for B+ wire
on rear of alternator
M8
15 Nm
56
AG.

ment
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M8 x 50
23 Nm
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M8 x 90
20 Nm
do
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Assembly overview - alternator, 2.0 l natural gas engine with air conditioning
system
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3.1.11

M5 x 21
4.5 Nm
M8
11 - Washer
M5
M4 x 19
2 Nm
M4 x 13
2 Nm
15 - Alternator
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16 - Poly V-belt
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Checking poly V-belt page
93
d
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Poly V-belt routing uPower
unit; Rep. gr. 13 ; Cylinder block, belt pulley
end; Assembly overview - poly
th
ra
a
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V-belt .
ss
3. Alternator
57
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Prote
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3.2
Removing and installing alternator
3.2.1 Removing and installing alternator, 1.2 l injection

lkswagen AG
n AG. Voengine
does
wage
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3.2.2 Removing and installing alternator,
1.4 l injection engine
ris
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t
without air conditioning system, page
61
au
es, in part or in w
l purpos
hole
ercia
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3.2.3 Removing and installing alternator, 1.4 l injection engine

t gu
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c
rrectness of i
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at
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his
3.2.4 Removing and installing alternator, 1.6 l injection engine,

page 65
3.2.5 Removing and installing alternator, 1.6 l diesel engine,
common rail (TDI), page 68
unit injector (TDI), page 71
common rail (TDI), page 78
unit injector (SDI), page 81
3.2.10 Removing and installing alternator, 2.0 l natural gas
engine, page 83
AG.
Make sure there is adequate clearance from all moving or

hot components.
Alternator on vehicles with Start/Stop system:
Until now the alternator and the voltage regulator were connected
together via their own wires to the engine and onboard supply
control unit. For vehicles with Start/Stop system, the information
transmission occurs via a LIN data bus to the diagnostic interface
for data bus. Via the CAN data bus, it supplies information to other
control units such as the engine control unit.
3.2.1
Removing and installing alternator, 1.2 l

injection engine with air conditioning
system
Caution

page 3 .
58
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Route electrical wiring so that original wiring layout is re

stored.
ht
rig
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Co
t.
Please note the following points during all assembly work, in

particular in the engine compartment, due to the narrow instal
lation conditions:
do
c
um
en
Caution

es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
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erm
o
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a
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rrectness of i
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at
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Removing:
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Remove poly V-belt Power unit; Rep. gr. 13 ; Cylinder block,

belt pulley end; Removing and installing poly V-belt .
Unscrew the two securing bolts of air conditioner compressor
-arrows-.
do
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Prote
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by
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.
C
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Undo the third bolt -arrow- and remove air conditioner com
pressor from bracket.
Note
The hoses of the air conditioner compressor can remain con
nected.
Suspend the air conditioner compressor -3- using a piece of
wire -1- at a suitable position under the vehicle until it is ready

to be reinstalled.
Ensure that the hoses -2- are not stretched or kinked.

Pull off protective cap -arrow-.
3. Alternator
59

Unscrew securing nut behind it and remove battery positive
cable from alternator.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Undo bolts securing alternator -arrows-.

Remove alternator by taking it downwards out of the vehicle.
Installation is carried out in reverse order of removal. Observe the
following when doing this:
agen
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AG.
Prote
cted
by
c
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C
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Caution
When fitting used poly V-belts observe the direction of ro

tation marked on removal!
Before installing poly V-belt, make sure that all ancillaries
(alternator, air conditioner compressor) are firmly secured
in place.
When fitting belt, ensure that poly V-belt seats correctly in

pulleys!
Drive threaded sleeve -A- about 4 mm in -direction of arrowout of alternator housing.
Start engine and check belt running.
60
ht
rig
py
Co
t.
Installing:
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
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a
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Undo bolt securing the guide roller -arrow- and remove guide
roller.
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3.2.2

injection engine without air conditioning
system
Caution

page 3 .
Tensioning lever - 3297-
es, in part or in w
l purpos
hole
ercia
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erm
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his
Removing:
ht
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Release and disconnect connector of DF cable -1- and pull off

protective cap -2-.
do
c
um
en

3. Alternator
61
AG.
Prote
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by

Unscrew B+ wire -arrow- from alternator.
AG. Volkswagen AG d
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is
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Unscrew wire holder -arrow- from alternator.

Take out alternator.
Installing:
Caution
When installing used poly V-belts observe the direction of

rotation marked on removal!
r
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iva
r
rp
fo
g
n

pulleys!
ht
rig
py
Co
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agen
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Prote
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by c
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Drive threaded sleeve -A- about 4 mm in direction of arrow out

of alternator housing.
AG.
62
do
c
um
en
Before installing poly V-belt, ensure that all ancillaries (al

ternator, air conditioning compressor) are securely fitted.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
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com
pe
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itte
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Secure wiring retainer -arrow- on back of alternator in 9 o'clock
position.
3.2.3

injection engine with air conditioning
system
Caution

kswagenadhered
scribed in the workshop manual should
to
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page 3 .
k
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Special tools and
by
ed
ris
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workshop
equipment
ss
rrectness of i
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nform
spec
at
i
h re
o
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wit
in t
his
Locking pin - T10060-
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Removing:
3. Alternator
63

protective cap -2-.
Unscrew B+ wire -arrow- from .alternator.

Volkswage
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ks
Remove noise insulation
General body repairs,
t gu
Vol
by front; Noise insulation .
ara
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Rep. gr. 50 ; iBody
n
se
tee
r
ho
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
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com
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rm
itte
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un
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or
Remove spoly
ac
au V-belt Power unit; Rep. gr. 13 ; Cylinder block,
s
c
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AG.
Prote
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by
Installing:
agen
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following:
Caution
When fitting used poly V-belts, take note of the direction

of rotation as marked during removal!
ternator, air conditioner compressor) are secure.
pulleys!
64

ua
ran
tee
or
ac
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
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m
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com
pe
rm
itte
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db
ise
r
tho
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Drive threaded sleeve -A- about 4 mm in direction of arrow

G. Volkswagen AG d
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position.
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injection engine
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AG.
3.2.4
do
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Caution

page 3 .
3. Alternator
65

Removing:
Pull off engine cover panel upwards -arrows-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
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t
a
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n
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Remove bracket -arrow- upwards.
agen
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66
do
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protective cap -2-.

Remove securing bolts -arrows-.
ht
rig
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Co
t.
r
fo
ng
Remove bracket together with tensioning device from the ve

hicle.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
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is n
mer
m
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or
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a
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p
un
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Unclip
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coolant hose from hose retainer -1- and undo nut -2-.
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3. Alternator
67

Remove alternator.
Installing:
following:
Caution
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an
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un
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Before installing poly V-belt, ensure that alls ancillaries (al
c
s

r
fo
ng
3.2.5

diesel engine, common rail (TDI)
Caution

page 3 .
68
AG.
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rig
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.
C
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Co
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position.
rrectne
s
s
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f
i
t to the co
n
form
spec
atio
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n
wit
i
n
thi
sd
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is n
mer
m
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erm
or
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t
a
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p

pulleys!

Removing:
Move lock carrier to service position General body repairs,
exterior; Rep. gr. 50 ; Lock carrier, up to 2011; Moving to and
back from service position or General body repairs, exterior;
Rep. gr. 50 ; Lock carrier, as of 2011; Moving to and back from
service position .
ility
ab
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an
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Note
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
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c
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erm
o
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a
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du
p
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nl
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n
Unscrew securing bolts of air conditioner

-arrows-.
AG. Volkswagen AG d
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i
r
compressor
o
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h
ut
ra
a
c
s
s
nected.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
The hoses of the air conditioner compressor can remain con

Hang up air conditioner compressor somewhere suitable with
a wire until it is reinstalled.
Ensure that the hoses are not stretched or kinked.
do
c
um
en
ht
rig
py
Co
t.
3. Alternator
69
agen
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AG.
Prote
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by c
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Release and disconnect connector of DF cable -1-.
Lever off deflector cap -2-.
Undo nut -1- and detach the B+ wire under it from the con
necting thread of the alternator.
Undo nuts -3- and remove cable bracket -2- from alternator.
Unscrew the lower of the two bolts -1- by approx. 1 cm; the bracket
on fuel filter has a slit in it for installation and removal.
Undo and remove the two bolts -arrows- securing the alterna
tor.
Remove alternator by taking it upwards out of the vehicle.
Installing:
following:
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
Prote
cted
by
When fitting used poly V-belts observe the direction of ro

tation marked on removal!
AG.
Before installing poly V-belt, make sure that all ancillaries

(alternator, air conditioner compressor) are firmly secured
in place.
pulleys!
70
ht
rig
py
Co
t.
Caution
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Note
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
Undo the two securing bolts -1- and the nuts -2- of the fuel filter
-3- and place fuel filter to one side. The fuel hoses can then
remain connected.
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AG. Volkswagen AG d
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db
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a
ss
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
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com
pe
rm
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ility
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Drive threaded sleeve -A- about 4 mm in direction of arrowenout

AG. Volkswagen AG d
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position.
agen
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.
C
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diesel engine, unit injector (TDI)
ht
rig
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Co
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AG.
Prote
cted
by
3.2.6
do
c
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r
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Caution

page 3 .
3. Alternator
71

Removing:
Pull off engine cover panel upwards -arrows A- and forwards
-arrow B-.
Note
ility
ab
y li
an
pt
ce
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
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or
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t
a
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iv
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nl
f
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ng
. Volkswagen AG
gen AG
does
swa
k
not
l
o
All hose connections of charge air system are secured
with
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b
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spring-type clips or push-on couplings. The following
instruc
e
nte
is
r
o
eo
tions must be complied with for push-on couplings:
h
ut
ra
a
c
s
Release push-on connection by pulling ssecuring ring -arrow-.
Pull off hose/pipe without tools.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Disconnect push-on couplings -1-.
Unclip fuel hoses -2- and remove charge air hose.
ht
rig
py
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Prote
cted
by
c
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rig
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.
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thi
sd
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cu
m
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72

Pull vacuum hose -1- off.
Disconnect connector -2-.
Remove bolt -arrow-.

Undo bolt securing charge air pipe -arrow-.
AG. Volkswagen AG d
agen
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Take charge air pipe out upwards.
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Disconnect push-on coupling of charge air pipe -arrow-.
3. Alternator
73

Disconnect connector of DF cable -1- and pull off protective
cap -2-.
rrectness of i
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nf
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spec
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Pull fuel filter out of holding bracket and place to one side.
When doing this, the fuel hoses can remain connected.
Caution

pulleys!
74
Prote
cted
by
following:
AG.
Installing:
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Note
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position.
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Drive threaded sleeve -A- Vabout
olks 4 mm in direction of arrow
gu
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of alternator housing. ed
n
All hose connections of charge air system are secured with
spring-type clips or push-on couplings. The following instruc

tions must be complied with for push-on couplings:
Push on hose or pipe without tools.

Ensure that retaining lugs have securely engaged -arrow-.
3.2.7

diesel engine, unit injector (TDI)
Caution

page 3 .
3. Alternator
75

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Locking pin - T10060 A-
Removing:
Pull engine cover panel off upwards -arrows-.
do
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service position .
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Caution
Before removing, mark the top side and direction of rotation of

the poly V-belt. When installing, ensure correct fitting position
and direction of rotation. If the belt is installed in the wrong
position or against direction of rotation, the belt will be de
stroyed!
76

Unscrew both securing bolts -1- and securing nut -2- and place
fuel filter -3- to one side. The fuel hoses can then remain con
nected.
Unscrew upper securing bolt -2- of alternator.
Open lower spring-type clip -1-.
Lever off deflector cap -2-.
Undo securing nuts -4- and remove cable bracket from alter
nator.
rrectness of i
t to the co
nform
spec
at
i
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in t
his
Undo nut -1- and detach the B+ wire under it from the con
necting thread of the alternator.
do
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Unlock and separate connector of DF cable -3-.
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alternator -3- forwards.
3. Alternator
77
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Unscrew lower securing bolt -1- of alternator.
Remove alternator by taking it upwards outVof
the vehicle.
olkswa
Installing:
Caution
rrectness of i
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nf
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spec
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wit
When installing used poly V-belts observe the direction of

rotation marked on removal!
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ternator, air conditioning compressor) are secure.
pulleys!
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sembly overview.
Specified torques
3.1.7 Assembly overview - alternator, 2.0 l diesel engine,
3.2.8

diesel engine, common rail (TDI)
Caution

page 3 .
78
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position.
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Install in the reverse

following:
gen AG
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Removing:
service position .
Remove charge air pipe above alternator.
Pull off protective cap -2-.
rrectness of i
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nf
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spec
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wit
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3. Alternator
79
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Unbolt fuel filter, and lay it to one side. When doing this, the
fuel hoses can remain connected.
does
not
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belt pulley end; Removing andeninstalling
.
agen V-belt
AG. Volkswpoly
AG
rrectness of i
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Installing:
Prote
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following:
agen
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by
AG.

Caution

pulleys!
80
do
c
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3.2.9

diesel engine, unit injector (SDI)
Caution
un
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scribed in the workshop manual should be strictly adhered
ir se to
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or
page 3 .
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Removing:
-arrow B-.
3. Alternator
81
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Caddy 2004 , Caddy 2011 s
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Electrical system - Editionu10.2014
th
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rrectness of i
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nf
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spec
atio
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wit

Pull fuel filter out of holding bracket and place to one side.
When doing this, the fuel hoses can remain connected.
AG.

Installing:
following:
82
agen
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Caution

pulleys!
3.2.10
Removing gand
Volkswagen AGalternator, 2.0 l
AG.installing
does
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Caution
ss

page 3 .
rrectness of i
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nf
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thi
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3. Alternator
83
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Removing:
WARNING
Any work to be done on the high-pressure lines of the natural

gas system must be carried out by fully trained personnel.
Remove bracket -arrow- upwards.

Unscrew cable holder -3- from alternator.
AG. Volkswagen AG d
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84

Undo lower bolt securing alternator -arrow-.
AG. Volkswagen AG d
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Undo upper bolt securing alternator -1-.
o
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s
Remove alternator by taking it upwards
out
of
the
vehicle.
s
Remove hexagon nut -2-.
Caution
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es, in part or in w
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The space between the low-pressure line and the lock carrier
is just big enough to allow removal of the alternator.
The alternator must be removed from the vehicle very carefully
in order to avoid damage to the low-pressure line leading to the
gas rail.
The low-pressure line to the gas rail must not be opened to
remove the alternator.
Installing:

AG.
Prote
cted
by

pulleys!
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ternator, air conditioner compressor, vane pump) are se
cured tightly.
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thi
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en
Caution
The alternator must be installed carefully in order to avoid

any damage to the low-pressure line to the gas rail.
3. Alternator
85

Secure wiring retainer -arrow- on back of alternator in 12
o'clock position.
sembly overview:
Vehicles without air conditioner page 55
Vehicles with air conditioning system page 56
AG. Volkswagen AG d
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Checking alternator
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3.3
3.3.1 Checking alternator, page 86
3.3.1
rrectness of i
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nform
spec
at
i
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in t
his
3.3.2 Functional check of poly V-belt pulley with freewheel on

alternator, page 86
Checking alternator

Body
Electrical system
27 - Starter, current supply
Functional check of poly V-belt pulley

with freewheel on alternator
AG.
The freewheel of the poly V-belt pulley on alternator is an impor

tant component of the belt drive and should always be checked if
damage to the belt drive/alternator is suspected.
Functional check of poly V-belt pulley with freewheel on alternator
Electrical system, General information; Rep. gr. 27 ; Alternator;
Functional check of poly V-belt pulley with freewheel on alterna
tor .
86
agen
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3.3.2
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C - Alternator
do
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Electrical components

3.4
Repairing alternator
3.4.1 Removing and installing voltage regulator, manufacturer

Bosch, page 87
3.4.2 Removing and installing voltage regulator, manufacturer
Valeo, page 88
3.4.3 Removing and installing poly V-belt pulley without free
wheel, page 89
3.4.4 Removing and installing poly V-belt pulley with free
wheel, manufacturer Bosch, page 90
3.4.5 Removing and installing poly V-belt pulley with free
wheel, manufacturer Valeo, page 91
3.4.1
Removing and installing voltage regula

tor, manufacturer Bosch
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rrectness of i
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atio
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Removing:
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Remove alternator page 58 .
Unscrew securing bolts and nuts -arrows- and remove pro

tective cap from alternator.
thi
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Undo bolts securing voltage regulator -arrows-.
Carefully remove voltage regulator from alternator.

Installing:
following:
Tighten threaded connections to specified torque page 44 .
3. Alternator
87
un
le
pe
rm
itte
d
Removing and installing voltage regula

tor, manufacturer Valeo
rrectness of i
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spec
a
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wit
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3.4.2
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Caddy 2004
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ran
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Electrical
h system - Edition 10.2014
t
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Removing:
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Remove clamping rings -arrows- and remove protective cap

from alternator.
agen
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AG.
Prote
cted
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Unscrew securing bolts of voltage regulator -arrows-.

Carefully remove voltage regulator from alternator.
Installing:
following:
Release locking lugs -arrows- and pull off protective cap from
voltage regulator.
Push carbon brushes into housing of voltage regulator and in
sert voltage regulator into alternator.
88
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Torque wrench - V.A.G 1783/-

Push protective cap into guides -arrows- until it can be heard
to engage.
3.4.3
Removing and installing poly V-belt pul

ley without freewheel

Socket - VAS 3310-
es, in part or in w
l purpos
hole
ercia
, is n
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ot p
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erm
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rrectness of i
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at
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Clamp alternator in a vice at securing points.
do
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3. Alternator
89
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es n
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Electrical system - Edition 10.2014y Vo
or
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Installing:
ua
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es, in part or in w
l purpos
hole
ercia
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or
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t
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b
ed
ris
o
Use socket - VAS 3310- to unscrew
th poly V-belt pulley securing
au
nut from alternator shaft.
ss
rrectness of i
t to the co
nf
o
r
m
spec
atio
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n in
wit
Installation is carried out in the reverse order. When installing ob

serve the following:
3.4.4

ley with freewheel, manufacturer Bosch

Multipoint adapter - VAS 3400-
AG.
Prote
cted
by

Remove protective cap from poly V-belt pulley with freewheel.
Note
The thread on the alternator shaft is a right-handed thread. To

undo the threaded connection, the shaft on the inside has to be
twisted out of the fixed pulley. This means that the nut is not un
screwed from the fixed bolt but the bolt is unscrewed from the
fixed nut, hence the changed direction of rotation.
90
agen
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.
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t.
Removing:
thi
sd
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en

Insert multi-point adapter - VAS 3400- with ring spanner 17
mm in poly V-belt pulley with freewheel of alternator.
Insert M10 multi-point bit -1- into alternator shaft.
Undo bolted connection by turning it clockwise and counter
holding with ring spanner.
Hold poly V-belt pulley with freewheel stationary
by
swagenand
olkhand
AG. V
AG do
agenpulley with free
es n
turn input shaft of alternator until polyolV-belt
ksw
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wheel can be removed.
b
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Installing:
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
First screw poly V-belt pulley with freewheel on drive shaft of

alternator by hand as far as limit stop.
The torque wrench - V.A.G 1332- must be modified for assembly
of poly V-belt with freewheel as follows:
Release socket drive -1- and pull off grip -2-.

Turn torque wrench grip -2- 180 and reinsert socket drive.
Set turning direction of torque wrench to anti-clockwise at
socket drive.
ht
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t.
agen
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Insert M10 multi-point bit -1- into alternator shaft.
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Counterhold adapter - VAS 3400- using 17 mm ring spanner.

Tighten poly V-belt with freewheel by turning drive shaft of al
ternator anti-clockwise using torque wrench - V.A.G 1332- .
3.4.5

ley with freewheel, manufacturer Valeo
3. Alternator
91

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TORX driver bit - V.A.G 1603/1Removing:

Remove protective cap from poly V-belt pulley with freewheel.
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The thread on the alternator shaft is a right-handed thread. To

undo the threaded connection, the shaft on the inside has to be
twisted out of the fixed pulley. This means that the nut is not un
screwed from the fixed bolt but the bolt is unscrewed from the
fixed nut, hence the changed direction of rotation.
Undo bolted connection by turning it clockwise and counter

holding with ring spanner.
Hold poly V-belt pulley with freewheel stationary by hand and
turn input shaft of alternator until poly V-belt pulley with free
wheel can be removed.
Installing:
following:
First screw poly V-belt pulley with freewheel on drive shaft of
alternator by hand as far as limit stop.
The torque wrench - V.A.G 1332- must be modified for assembly
of poly V-belt with freewheel as follows:
92
AG.
Insert TORX driver bit - V.A.G 1603/1- into alternator shaft.
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Insert multi-point adapter - VAS 3400- with ring spanner 17

mm in poly V-belt pulley with freewheel of alternator.
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Multipoint adapter - VAS 3400-

Release socket drive -1- and pull off grip -2-.
Turn torque wrench grip -2- 180 and reinsert socket drive.
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Set turning direction of torque wrench to anti-clockwise at

socket drive.
Insert TORX driver bit - V.A.G 1603/1- into alternator shaft.
rrectness of i
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spec
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Counterhold adapter - VAS 3400- using 17 mm ring spanner.

Tighten poly V-belt with freewheel by turning drive shaft of al
ternator anti-clockwise using torque wrench - V.A.G 1332- .
Crank engine at vibration damper/belt pulley using a socket.
AG.
Prote
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by
Check poly V-belt for:
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Sub-surface cracks (cracks, core ruptures, cross sectional

breaks)
Layer separation (top layer, cord strands)
Base break-up
Fraying of cord strands
Flank wear (material wear, frayed flanks, flank brittleness glassy flanks-, surface cracks)
Traces of oil and grease
Caution
In order to avoid failures and malfunctions, the poly V-belt must

be replaced if it is damaged.
3. Alternator
93

Cruise control system (CCS)
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General information on cruise control system (CCS) is available

in the workshop manual Electrical system, General information
Electrical system, General information; Rep. gr. 27 ; Cruise
control system (CCS) .

Start/Stop system
5.1 General description - Start/Stop system, page 95

5.2 Removing and installing start-stop mode switch,
page 96
5.3 Removing and installing voltage stabiliser, page 96
5.4 Removing and installing battery monitoring control unit,
page 100
5.1
General description - Start/Stop system

Note
Additional information:
Operating manual of vehicle
Self-study programme No. 426 ;
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Start/Stop system
2009
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General description:
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.
Fault detection and fault display:
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
fault finding.
For fault finding, use the systems described in chapter Vehicle
diagnosis, testing and information system in Guided Fault Find
ing mode page 403 .
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When recharging or jump starting vehicles with Start/Stop sys

tem, note the following: first connect charging cable to battery
positive terminal, then body earth. This ensures that the battery
monitoring control unit 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.
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Battery recharging or jump start on vehicles with Start/Stop sys

tem:
rrectne
s
s
o
f
i
t to the co
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form
spec
atio
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n
wit
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Current flow diagrams, Electrical fault finding and Fitting loca

tions

ard components.
5. Start/Stop system
95

Following components are involved in the Start/Stop system:
Battery - A Alternator - C- page 44
Voltage regulator - C1 Starter - B- page 12
Brake light switch - F Clutch pedal switch - F36 Start/stop operation switch - E693- page 96
Coolant temperature sender - G62 Accelerator position sender - G79 Gearbox neutral position sender - G701 Control unit for ABS with EDL - J104 Climatronic control unit - J255 Control unit with display in dash panel insert - J285 page 101
Battery monitoring control unit - J367- page 100
Power steering control unit - J500 Onboard supply control unit - J519- page 382
Voltage stabiliser - J532- page 96
Data bus diagnostic interface - J533- page 387
Engine control unit - J623pe
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Removing and installing start-stop mode

switch
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5.2
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The start/stop operation switch - E693- is located in the centre

console switch unit in front of the gear lever. It serves to switch
off manually the Start/Stop system.
Removal and installation of the start/stop operation button - E693are carried out in the same way for all switches in the centre
console switch unit
4.1 Removing and installing buttons in centre console storage
compartment, page 332 .
5.3
Removing and installing voltage stabil

iser
5.3.1 General description - voltage stabiliser, page 96
5.3.3 Removing and installing voltage stabiliser J532 , righthand drive vehicles, page 98
General description - voltage stabiliser
Prote
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by
96
AG.
Due to the high current draw of the starter, voltage dips occur in
the onboard supply system each time the engine is started. To
prevent any failure in the infotainment components and the dash
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Role of voltage stabiliser:
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5.3.2 Removing and installing voltage stabiliser J532 , lefthand drive vehicles, page 97

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).
. Volkswagen AG
AG
Voltage stabiliser - J532- is fitted on left in dash panel behind relay
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carrier on onboard supply control unit - J519- (LHD).
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On RHD models, voltage stabiliser - J532- is fitted onuright
in dash
tho
a
panel behind relay carrier on onboard supply control
unit
- J519- .
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Effects in case of voltage stabiliser failure:
5.3.2
Removing:
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spec
at
i
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his
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 concerning
a malfunction of the voltage regulator, e.g. in the event memory
of the diagnostic 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.
Removing and installing voltage stabil

iser - J532- , left-hand drive vehicles
key.
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Unscrew nuts -arrows- and remove cover.
do
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Remove wiper frame with linkage and wiper motor

page 108 .
Installation position of voltage stabiliser - J532- -arrow-.
97

Press locking mechanism -arrow A- next to voltage stabiliser
on each side -arrows- and push voltage stabiliser in direction
of -arrow B- towards inside of vehicle.
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Remove voltage stabiliser -1- and release and disconnect

connector -arrow-.
Press release buttons -arrows A- outwards and push voltage

stabiliser -2- off bracket -1- in direction of arrow.
Installing:
Removing and installing voltage stabiliser - J532- , right-hand drive vehicles

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5.3.3
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Installation is carried out in reverse order of removal.
For reasons of clarity, the components in the magnified section are shown from the perspective of looking down
through the dash panel.
98

1 - Electrical connector
2 - Voltage stabiliser - J5323 - DC/DC bracket
4 - Rack assembly
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Removing:
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Note
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Remove onboard supply control unit - J519- , data bus diag

nosis interface - J533- , relay carrier (9 slot) and relay carrier
(5 slot) from assembly bracket (rack).
do
c
um
en
Remove assembly bracket (rack) complete with onboard sup

ply control unit - J519- , relay carrier (9 slot) and relay carrier
(5 slot).
When doing this, do not disconnect connectors of control units

and relay carriers.
Release and disconnect connector Item 1 (page 99) on volt
age stabiliser - J532- .
99

Press release buttons -arrows A- on DC/DC bracket (plastic
frame) -1- and push voltage stabiliser -2- off bracket in direc
tion of -arrow B-.
AG. Volkswagen
Installing:
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atio
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wit
5.4
Removing and installing battery moni

toring control unit
The battery monitoring control unit can only be replaced together

with the negative cable of the battery.
Removing:
key.
Release and disconnect connector -1- on battery monitor con
trol unit - J367- .
Loosen clamp bolt -arrow- at battery negative terminal and
unscrew negative cable securing nut -arrow- on right next to
battery.
Prote
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by
100
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Installing:
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Remove negative cable.
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Installation is carried out in
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of removal.
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90
Gauges, instruments
Dash panel insert
1.1 General description - dash panel insert, page 101

1.2 Renewing dash panel insert, page 102
1.3 Removing and installing dash panel insert, page 102
1.4 Connector pin assignment - dash panel insert,
page 103
1.5 Warning lamp symbols in dash panel insert, page 103
1.6 Coding dash panel insert, page 104
1.1
General description - dash panel insert

Note
Self-study programme No. 328 ; The Caddy 2004
tions
Integrated in the dash panel insert are the following components:
Control unit with display in dash panel insert - J285 Immobiliser control unit - J362 Speedometer
Rev. counter
To provide acoustic support to some of the visual displays, the

dash panel features a warning buzzer, which is actuated by the
control unit.
All warning lamps are fitted with light-emitting diodes (LEDs). No
provision is made for dash panel insert repair. If necessary, the
dash panel insert is renewed as a unit page 102 .
The data bus diagnostic interface - J533- (Gateway) is an indi
vidual control unit option and not part of the dash panel insert
page 387 , unlike on several other vehicles.
On vehicles manufactured up to week 22.09, the gateway
control unit and the onboard supply control unit are combined
to form one control unit.
The dash panel insert is equipped with self-diagnosis, which
makes fault finding easier.
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Co
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ing mode page 403 .
rrectne
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spec
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Warning lamps page 103
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Coolant temperaturethgauge
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Multifunction display
1. Dash panel insert
101
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Renewing dash panel insert

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1.2
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his

Body
Electrical system

Dash panel insert
Functions of dash panel insert
Adapting/renewing dash panel insert
Removing:
key.
Unclip steering column trim on dash panel insert.
Undo and remove bolts -arrows- securing dash panel insert
-1-.
For reasons of clarity, the steering wheel is not shown on the il
lustration.
Pull dash panel insert -1- out of dash panel.
Note
Vehicles up to and including model year 2010: Connectors do
not have to be disconnected before the dash panel insert is

pulled out. The electrical connector is permanently fitted in the
vehicle and is automatically disconnected when dash panel
insert is pulled out.
Vehicles as of model year 2011: After dash panel insert has
been pulled out, the connector on the rear of the dash panel
insert must be released and disconnected.
Installing:
102
Rep. gr.90 - Gauges, instruments
AG.
Before removing the dash panel insert, the

1.2 Renewing dash panel insert, page 102 work procedure
should always be carried out in order that the data stored in the
control unit can be read.
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Note
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Removing and installing dash panel in

sert
do
c
um
en
1.3

1.4
Connector pin assignment - dash panel

insert
Note
The dash panel insert must not be dismantled. If necessary, the

dash panel insert is renewed as a unit.
1-
Connector, 36-pin
2-
Warning buzzer
Connector pin assignment for dash panel insert: Current flow

diagrams, Electrical fault finding and Fitting locations
1.5
Warning lamp symbols in dash panel insert
1 - Electric On Board Diagno

sis (EOBD)
2 - E-gas (electronic throttle)
3 - Immobiliser
4 - Charge control
5 - Bulb failure
6 - Rear fog light
7 - Left turn signal switch
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9 - Brake pad wear
Vol
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d
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The brake pad
ris wear in
homore instal
t
dicator is no
au
ss
led on Caddy
base vehi
cles/light commercial
vehicles with Lowline
dash panel insert as of
06.2007.
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8 - Low coolant level/coolant

overheating
1. Dash panel insert
103
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10 - Washer fluid level
11 - Fuel reserve
12 - Right turn signal switch
13 - Airbag display
14 - Driver seat belt
15 - Anti-lock brake system
(ABS)
16 - Electronic stabilisation
programme (ESP)/Traction
control system (TCS)
17 - Brake fault/handbrake
18 - Cruise control system
21 - Shift lock
23 - Bonnet open
24 - Door open
25 - Oil pressure
26 - Main beam
27 - Turn signal switch for trailer
28 - Side lights
29 - Steering
un
le
Coding dash panel insert
r
fo
ng

Body
Electrical system
Dash panel insert
Functions of dash panel insert
104
Rep. gr.90 - Gauges, instruments
AG.

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1.6
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spec
atio
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i
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thi
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22 - Oil level
ole,
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20 - Rear seat backrest lock
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19 - Tyre pressure monitoring (TPM)
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Horn
2.1 Removing and installing treble horn and bass horn , page
105
n AG. Volkswagen AG do , page 105
2.2 Checking treble
es
wage horn and bass horn
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Removing and installing treble horn and

bass horn
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The treble horn - H2- and the bass horn - H7- are actuated in
The procedure for removal and installation of the treble horn -
H2- and the bass horn - H7- is the same and is therefore
described for just one horn.
The horns can be found on the left and right next to the longi
tudinal members.
Removing:
key.
Release and disconnect electrical connector -arrow-.
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Unscrew securing bolt -arrow- and remove horn together with

bracket.
Installing:
2.2
Checking treble horn and bass horn
The horns ( treble tone horn - H2- and bass tone horn - H7- ) can
be checked in final control diagnosis by the onboard supply con
trol unit - J519- .
2. Horn
105

92
Windscreen wash/wipe system
Windscreen wiper system
1.1 Moving wipers to service position, page 106

1.2 Deactivating APP function of wiper motor, page 106
1.3 Removing and installing wiper arms, page 107
1.4 Removing and installing wiper frame with linkage and wiper
motor, page 108
1.5 Removing and installing wiper motor, page 110
1.6 Removing and installing wiper blades, page 111
1.7 Renewing windscreen wiper rubber, page 112
1.8 Adjusting windscreen wiper park position, page 113
1.9 Removing and installing rain and light sensor, page 114
1.10 Coding rain and light sensor, page 117
1.1
Moving wipers to service position
To remove wiper blades, wiper arms must be moved to service/

winter position. The service/winter position is activated within
10 seconds after ignition is switched off by pressing windscreen
wiper lever in flick wipe position Operating manual of vehicle .
pe
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Deactivating APP function of wiper mo

tor
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1.2
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The windscreen wiper system is equipped with an APP function

(alternating park position).
With the APP function, the wiper arm is moved up slightly once it
has reached the lowest position. This occurs every second time
the windscreen wiper system is switched off.
To install the motor crank on the wiper motor, it is necessary for
the motor to be in the lowest park position. To ensure this position
is reached, the APP function must be deactivated.
Note
The APP function cannot be activated.

After 100 cycles of wiper movement, the APP function is acti
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Rep. gr.92 - Windscreen wash/wipe system
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do
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vated automatically. This applies to wiper motors whose APP

function has been deactivated and also to new wiper motors.

Body
Electrical system
Onboard supply control unit
Functions - onboard supply control unit
Coding wiper electronics control unit / deactivating APP func
tion
Read out current code and make a note of the reading.
Code control unit with noted reading.
Note
The reading can vary in the number of figures from the number
of spaces available for the new code. This has absolutely no
bearing on the function of the windscreen wiper system. The new
coding simply has the effect of resetting the wiper cycle counter
to zero.
1.3
Removing and installing wiper arms
Removing:
Deactivate APP function page 106 .
Move windscreen wipers to park position. Then, switch off ig
nition and all electrical loads, and pull out ignition key.
do
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Lever off cap -arrow- using screwdriver.
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1. Windscreen wiper system
107
AG.
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Loosen nut -arrow- without screwing it off completely.
Fold up wiper arm and release it from taper by rocking arm
back and forth sideways.
Now, unscrew securing nut completely and remove wiper arm.
Installing:
following:
Fit wiper arms on driver and front passenger sides onto their
shafts.
Screw securing nut loosely onto wiper arm shaft.
Note
The securing nut of the wiper arm shaft
should not be tightened
G. Volkswage
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aposition
until the wiper blade parking
has been
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If wiper arms are secured
with self-locking nuts, these mustarabe
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After the wiper blade park position has been adjusted, tighten
securing nuts of wiper arms to 20 Nm.
Fit caps.
1.4
Removing and installing wiper frame

with linkage and wiper motor
Caution

page 3 .
AG.
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Adjust wiper blade park position page 113 .
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Release lever - 80-200-
Removing:

Removing wiper arm page 107 .

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Remove trim -1- from vehicle.
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Undo and remove bolts -arrows- securing trim -1-.
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Remove plenum chamber cover General body repairs, ex

terior; Rep. gr. 66 ; Removing and installing plenum chamber
cover .
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AG.

Unscrew securing bolts -arrows- and remove wiper frame -2towards front from vehicle.
Installing:
following:
109

When installing, fit guide pin located on back of wiper frame
into grommet -arrow- on plenum chamber bulkhead.
Tighten bolts securing wiper frame to body to 8 Nm.
Push connector onto connection of wiper motor and engage
it.
Install air duct trim.
Connect battery page 3 .
Install plenum chamber cover General body repairs, exte
rior; Rep. gr. 66 ; Removing and installing plenum chamber
cover .
1.5
Removing and installing wiper motor
The wiper motor control unit - J400- and the wiper motor - V- are
combined to form one unit.
Removing:
page 108 .
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Lever rods -arrow- off motor crank using removal lever
lksw
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80-200- .
by
Pull motor crank -2- off wiper motor shaft.

Unscrew securing bolts -arrows- and remove wiper motor to
gether with control unit from wiper frame.
Installing:
Insert wiper motor into wiper frame and tighten bolts securing
wiper motor to wiper frame to 8 Nm.
Prote
cted
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110
AG.
Install wiper frame with linkage and wiper motor page 108 .
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Screw on nut -3- securing motor crank to shaft of wiper motor

and tighten it to 18 Nm.
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Fit motor crank -1- onto shaft of wiper motor. Distance -a- to
limit stop -2- should be 3 1 mm.
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following:

1.6
Removing and installing wiper blades
1.6.1 Removing and installing joint-free wiper blades without

TOP-Lock catch, page 111
1.6.2 Removing and installing joint-free wiper blades with TOPLock catch, page 111
1.6.1
Removing and installing joint-free wiper

blades without TOP-Lock catch
Note
Driver and front passenger wiper blades must not be inter
changed during installation.
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 windscreen wipers.
To remove wiper blades, wiper arms must be moved to serv
ice/winter position. The service/winter position is activated

within 10 seconds after ignition is switched off by moving
Volkswagen AG
n AG. the
does
wage 106 .
windscreen wiper lever to flick wipe position olkspage
not
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Fold up wiper arm.
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Move wiper arms to service/winters position page 106 .
gu
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Turn wiper blade -1- on wiper arm as far as stop -arrow A-.
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his
Pull wiper blade -1- off wiper arm axis -arrow B-.
Installing:
Push wiper blade onto wiper arm axis.

Turn wiper blade on wiper arm axis as far as stop.
Carefully fold wiper arm back onto windscreen.
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 windscreen wipers.
AG.
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Driver and front passenger wiper blades must not be inter
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Note
Removing and installing joint-free wiper

blades with TOP-Lock catch
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1.6.2
To remove wiper blades, wiper arms must be moved to serv
ice/winter position. The service/winter position is activated

within 10 seconds after ignition is switched off by moving the
windscreen wiper lever to flick wipe position page 106 .
Removing:
Move wiper arms to service/winter position page 106 .
111

Fold up wiper arm.
Press button -1- and pull wiper blade mounting -3- in
-direction of arrowout of wiper arm -2-.
Installing:
following:
Push wiper blade mounting -3- onto wiper arm -2- as far as
stop.
Ensure proper engagement of button -1- in wiper arm -2-.
Carefully fold wiper arm back onto windscreen.
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Renewing windscreen wiper rubber

es, in part or in w
l purpos
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1.7
1.7.1 Renewing windscreen wiper rubber, joint-free wind

screen wipers, page 112
Renewing windscreen wiper rubber,

joint-free windscreen wipers
Removing:
rrectness of i
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1.7.1
key.
Remove wiper blade page 111 .
Check to see on which side windscreen wiper rubber cannot

be moved in guide.
On that side, carefully lever off cap -1-.
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112

Bend windscreen wiper rubber stop -A- open using a suitable
screwdriver.
Now, renew windscreen wiper rubber.
Note
Ensure that windscreen wiper rubber is seated correctly in wiper

blade guides.
Using a suitable screwdriver, push windscreen wiper rubber

stop -A- back down until windscreen wiper rubber can no lon
ger be moved within guide.
es n
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Fit new cap -1b
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Installing: utho
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ss
1.8
Adjusting windscreen wiper park posi

tion

rrectness of i
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nf
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spec
atio
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wit
Ensure proper operation of wiper blade.
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Install wiper blade page 111 .
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following:
113
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Note
On right-hand drive vehicles, the wiper blades are a mirror-image

of those on left-hand drive vehicles.
Adjust windscreen wiper park position.
Driver side:
Distance -A- between windscreen wiper rubber and upper edge
of plenum chamber cover must be 30 mm.
Adjust windscreen wiper park position by moving wiper arm, if
necessary.
Tighten bolt for securing wiper arm to shaft of wiper motor to
20 Nm.
Front passenger side:
Distance -B- between windscreen wiper rubber and upper edge

of plenum chamber cover must be 30 mm.
Adjust windscreen wiper park position by moving wiper arm, if
necessary.
AG do
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Removing and installing rain and light

sensor
If an intact rain and light sensor - G397- is removed from its re

taining plate on the windscreen (e.g. renewing a windscreen) it
can be subsequently reinstalled. Store the removed rain and light
sensor - G397- in a dust-free location until reinstallation and en
sure the silicone contact pad is not soiled.
Removing:
AG.
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114
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Tighten bolt for securing wiper arm to shaft of wiper motor to

20 Nm.
G. Volkswagen

Unclip cover -1- of rain and light sensor - G397- together with
lower wiring cover at the detents -arrows-.
rrectness of i
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115
AG.
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Using a suitable plain slot screwdriver, lever rain and light
sensor - G397- -1- on recess -3- out of retaining plate -2-.
Note
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Caution
Prior to installation, thoroughly clean the surface of the

windscreen inside the bracket for rain and light sensor G397- . Any remains of coupling pad adhering to the
windscreen must be completely removed.
Remove protective cap of new rain and light sensor - G397- .

Insert rain and light sensor - G397- -1- into the retaining plate
on front windscreen -2- by pressing it in firmly.
Note
Even when sensor is installed correctly, small air bubbles may

first appear between windscreen and coupling pad. After approx.
10 minutes, the contact surface must be free of bubbles.
Engage clasps -3-.
116
AG.
Clean windscreen within retaining plate thoroughly; cleansing

agent General body repairs, interior; Rep. gr. 68 ; Interior
mirror; Bonding retaining plate for interior mirror with rain sen
sor .
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If the surface (coupling pad) of the rain and light sensor - G397is soiled, it may be possible to clean it by bonding on and then
pulling off one or more adhesive strips.
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Note
r
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ng
The surface (coupling pad) of the rain and light sensor G397- must not be soiled on installation. A sensor with
damaged coupling pad must be renewed.
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Installing:
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On removal, take care to lever out the entire rain and light sensor
- G397- and not just the upper shell of the sensor.

Connect electrical connector -A-.
Install cover of rain and light sensor - G397- .
Note
The cover of the rain and light sensor - G397- must first be
pushed under the headliner at the top and then engaged on

the retaining frame.
The cover must engage with the upper wiring cover securely
and over its complete length.
If necessary, code rain and light sensor - G397 page 117 .
1.10
Coding rain and light sensor

wagen AG testing and
eral information; Rep. gr. 97g;enVehicle
AG. Volksdiagnosis,
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information systems; Connecting
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Body
Electrical system
Functions
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Using GoTo
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117
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Windscreen washer system
2.1 Assembly overview - windscreen washer system,

page 118
2.2 Removing and installing washer fluid reservoir,
page 120
2.3 Removing and installing filler pipe for washer fluid reser
voir, page 123
2.4 Removing and installing windscreen and rear window
washer pump V59 , page 123
2.5 Removing and installing windscreen washer fluid level
sender G33 , page 125
2.6 Removing and installing windscreen spray jets,
page 127
2.7 Adjusting windscreen washer system spray jets,
page 127
2.1
Assembly overview - windscreen wash

Volkswagen AG
does
er system olkswagen AG.
no
In vehicles with auxiliary heater a washer fluid reservoir with a
different shape may be installed, depending on the vehicle

equipment.
ing the final control diagnosis of the onboard supply control

unit - J519- .
tions
Operating manual

ing mode page 403 .
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118
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The onboard supply control unit - J519- features a self-diagnosis

function that facilitates fault finding.
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The windscreen washer system function can be checked us
ility
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1 - Spray jet for windscreen

washer system
Depending on equip
ment with heater ele
ment for left washer jet Z20- or heater element
for right washer jet Z21- :
page 127
Adjusting page 127
2 - Angled piece
Connection to spray jet
for windscreen washer
system
Overview of hose cou
plings for washer fluid
lines page 154
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4 - Windscreen and rear win

dow washer pump - V59 Removing and instal
ling, vehicles without
auxiliary heater
page 123
Removing and instal
ling, vehicles with auxil
iary heater page 124
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3 - Y-piece
Distribution of wash wa
ter line to windscreen
washer system spray
jets
5 - Angled connection piece

Connection to wind
screen and rear window
washer pump - V59 Overview of hose couplings for washer fluid lines page 154
6 - Windscreen washer fluid level sender - G33 Removing and installing, vehicles without auxiliary heater page 125
Removing and installing, vehicles with auxiliary heater page 125
7 - Washer fluid reservoir
Removing and installing, vehicles without auxiliary heater page 120
8 - Filler pipe for washer fluid reservoir
Removing and installing page 123 .
9 - Hose
Hose repair page 155
2. Windscreen washer system
119
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Removing and installing washer fluid

reservoir
2.2.1 Removing and installing washer fluid reservoir, vehicles

without auxiliary heater, page 120
2.2.2 Removing and installing washer fluid reservoir, vehicles
with auxiliary heater, page 121
2.2.1

reservoir, vehicles without auxiliary
heater
Removing:
key.
Prote
cted
by
To disconnect connector of windscreen and rear window

washer pump - V59- -3-, swing windscreen and rear window
washer pump -5- slightly towards front and out of washer fluid
reservoir.
Separate hose connections -4- on windscreen and rear win
dow washer pump - V59- -3-.
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 fittings
must be connected to the correct colour-coded pump connections
during installation.
Unclip pipe from retainers on washer fluid reservoir.
Unscrew securing bolt -1- of washer fluid reservoir.
Unscrew securing nuts -2- of washer fluid reservoir.
Remove washer fluid reservoir by pulling it towards right out
of vehicle.
Installing:
After completing the installation work, bleed the headlight
washer system page 153 .
120
AG.
Disconnect connectors from washer fluid level sender -2- and

headlight washer system pump -1-.
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Detach hose at connecting pipe of headlight washer system

pump - V11- -7- and use a suitable container to collect the
washing fluid that comes out.
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Detach front bumper cover on right side until washer fluid res
ervoir is accessible General body repairs, exterior; Rep. gr.
63 ; Front bumper, up to 2011 or General body repairs,
exterior; Rep. gr. 63 ; Front bumper, as of 2011 .
thi
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Remove filler pipe for washer fluid reservoir page 123 .

2.2.2

reservoir, vehicles with auxiliary heater
Removing:
key.
Remove filler pipe for washer fluid reservoir page 123 .
Remove front bumper cover General body repairs,
olkswagen AG
. Vexterior;
gen AG
does
Rep. gr. 63 ; Front bumper, up to 2011 orolk
swaGeneral body
not
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gu
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repairs, exterior; Rep. gr. 63 ; Frontebumper,
as of 2011 .
ara
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Remove right headlight pageau166
ss
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Pull hose connections -1- off windscreen and rear window

washer pump and use a suitable container to collect the wash
ing fluid that comes out.
Unclip fastener -1- from wiring harness.
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Push window washer pump upwards in -direction of arrowand remove.
121

Unclip fasteners -1- and -2- from wiring harness.
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Unclip fuel line of auxiliary heater from retainer
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Unclip fuel line from retainers -1- and -2-.
On completion of installation work, bleed headlight washer

system page 153 .
122
AG.
following:
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Installing:
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Pull washer fluid reservoir towards front out of mountings.
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Unscrew securing bolts -1- and -2-.

2.3
Removing and installing filler pipe for

washer fluid reservoir
Note
Depending on vehicle equipment, two different washer fluid
reservoirs are used.
Therefore, the illustrations may differ. The filler tube is re
moved and installed in the same way for both versions.
Removing:
key.
Pull filler pipe -2- in -direction of arrow- off connection -3- on
washer fluid reservoir.
Installing:
following:
rrectness of i
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spec
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The protrusion on the underside of the filler pipe

ted in the hole -arrow-.
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and rear window washer pump - V59-
2.4.1 Removing and installing windscreen and rear window

washer pump V59 , vehicles without auxiliary heater,
page 123
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Removing:

and rear window washer pump - V59- ,
vehicles without auxiliary heater
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2.4.2 Removing and installing windscreen and rear window

washer pump V59 , vehicles with auxiliary heater, page 124
key.
123

Unclip fog light trim, or remove right fog light page 243 .
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washer pump - V59- -3- and use a suitable container
r
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the washing fluid that comes out.
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Disconnect connector -1- of windscreen and rear window

washer pump - V59- -3-. To do this, swing windscreen and rear
window washer pump -3- slightly towards front -arrow- and out
of washer fluid reservoir.
Pull windscreen and rear window washer pump - V59- -3- up

wards out of washer fluid reservoir.
Installing:
following:
Note
Removing:
key.
Detach front right wheel housing liner in front area General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Re
moving and installing front wheel housing liner .
washer pump and use a suitable container to collect the wash
ing fluid that comes out.
124
AG.

and rear window washer pump - V59- ,
vehicles with auxiliary heater
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2.4.2
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system page 153 .
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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 fittings
must be connected to the correct colour-coded pump connections

Push window washer pump upwards in -direction of arrowand remove.
Disconnect connector -1- at windscreen and rear window

washer pump.
Installing:
following:
Note
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The connections
V to the pump and hose linesotare
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by
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order to prevent
the
washer
fluid
lines
being
incorrectly
nte connected
is
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to theufront
and rear washer fluid pump - V59- . The ehose
fittings
t
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must
ss be connected to the correct colour-coded pump connections
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2.5
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system page 153 .

washer fluid level sender - G33-
2.5.1 Removing and installing windscreen washer fluid level

sender G33 , vehicles without auxiliary heater, page 125
2.5.2 Removing and installing windscreen washer fluid level
sender G33 , vehicles with auxiliary heater, page 126
2.5.1

washer fluid level sender - G33- , vehi
cles without auxiliary heater
Removing:
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The windscreen washer fluid level sender - G33- is installed in the

washer fluid reservoir before the front right wheel housing.
Prote
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key.
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Unclip cover of right fog light, or remove fog light

page 243 .
125
AG.

Release and disconnect connector -1- on windscreen washer
fluid level sender - G33- .
Pull windscreen washer fluid level sender - G33- -2- out of its
rubber seal.
Collect escaping fluid in a suitable container.
Installing:
following:
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p

washer fluid level sender - G33- , vehi
cles with auxiliary heater
The windscreen washer fluid level sender - G33- is installed in the

washer fluid reservoir before the front right wheel housing.
Removing:
key.
Caution
Carefully pull off bumper. When doing this, ensure that the
bumper is not being deformed or torn.
Unscrew bolts -4- and -5- of right wheel housing.

Unscrew bolts -6- from below.
Release catches at top of radiator grille from lock carrier.
Further removal is only possible with a second mechanic.
Pull front bumper cover -1- on the right side out of catches of
guides on wing -arrows a- until the windscreen washer fluid
level sender - G33- is accessible.
126
AG.
Unscrew bolts -3- of right wheel housing (facing upwards).
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Unscrew bolts -2-.
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Risk of damage to component.
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2.5.2
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AG. Volkswagen AG d
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Release and disconnect connector -2- on windscreen washer
fluid level sender - G33- .
. Volkswage
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wage
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s no
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Pull windscreen washer
level sender - G33- -1out
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yV
b
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rubber seal in washer
fluid
reservoir.
e
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i
Installing:
tee
or
ac

system page 153 .
2.6

spray jets
Removing:
key.
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Push spray jet upwards -arrow A- and pull it out of bonnet at

rear -arrow B-.
rrectne
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t to the co
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spec
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following:
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Pull hose -1- off spray jet, and release and disconnect con
nector -2-.
Installing:
Fit connector -2- and hose -1- onto spray jet.
Push spray jet into mounting hole until it locks in place audibly.
Adjusting spray jets page 127
2.7
Adjusting windscreen washer system

spray jets
Note
In case of uneven spray field due to impurities in the spray jet:
remove spray jet and rinse it through with water in both direc
tions.
Purging the spray jet with compressed air in both directions is
then permitted.
Do not use any objects for cleaning spray jets!
127

AG. Volkswagen AG d
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128
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Adjusting windscreen washer system spray jets Maintenance ;

Booklet ; Descriptions of work

Rear window wiper system
3.1 Assembly overview - rear window wiper system,

page 129
3.2 Removing and installing rear window wiper arm,
page 131
. Volkswagen AG wiper motor,
3.3 Removing and installing
gen AG rear window
does
swa
k
not
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page 133
gu
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b
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ara
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ris rear window wiper park position, pagete135

3.4 Adjusting
eo
tho
au
3.1
Assembly overview - rear window wiper

system
3.1.1 Assembly overview - rear window washer system, vehi

cles with rear lid, page 129
3.1.2 Assembly overview - rear window wiper system, vehicles
with rear wing doors, page 130
3.1.1
Assembly overview - rear window wash

er system, vehicles with rear lid
Note
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Co
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3.6 Renewing rear window wiper rubber, page 137
ra
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ss
3.5 Removing
and installing rear window wiper blade,
page 136
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tions
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Operating manual

ing mode page 403 .
3. Rear window wiper system
129

1 - Cover cap
2 - Hexagon nut, AF 13 mm
Rear window wiper arm
to shaft of rear window
wiper motor
12 Nm
3 - Rear window wiper arm
page 131 .
Adjusting park position
page 135 .
4 - Seal
5 - Spray jet
page 144 .
Adjusting page 144
6 - Seal
7 - Rear window wiper motor es n
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page 133 . au
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9 - Rubber ring
10 - Spacer
11 - Rear window wiper

rear window wiper page 136 .
Renewing rear window wiper rubber page 137 .
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Assembly overview - rear window wiper

system, vehicles with rear wing doors
AG.

tions
Operating manual
ing mode page 403 .
130
ht
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3.1.2
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spec
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8 - M6 hexagon nut with wash

er
Rear window wiper mo
tor to rear lid
8 Nm
un
le
2 - Hexagon nut, AF 13 mm
Rear window wiper arm
to shaft of rear window
wiper motor
12 Nm
AG.
Prote
cted
by
7 - M6 hexagon bolt with wash

er
Rear window wiper mo
tor to rear wing door
8 Nm
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6 - Rear window wiper motor V12 Removing and installing

page 134 .
c
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5 - Spray jet
page 144 .
Adjusting page 144
ht
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4 - Seal
r
fo
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3 - Rear window wiper arm

page 131 .
Adjusting park position
page 135 .
rrectne
s
s
o
f
i
t to the co
n
form
spec
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1 - Cover cap
es n
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ua
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ran
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tee
Caddy
2004
, Caddy
2011
o
h
t
or
u
a
a
Electrical
system
Edition
10.2014
c
ss
8 - Rubber ring
9 - Spacer
10 - Rear window wiper
Renewing rear window
wiper rubber
page 138 .
3.2
Removing and installing rear window

wiper arm

Removing:
Move wipers to park position.
131

key.
Fold cover cap -1- of rear window wiper up and unclip it.
Loosen nut -arrow- without screwing it off completely.
Fold wiper arm up and release from taper by rocking arm back
and forth sideways.
Undo nuts -arrows- and remove wiper arm

Installing:
following:
To place wiper motor in its rest position, switch rear wind
screen wiper on and off with ignition on.
Switch off ignition and remove ignition key.
Fit rear window wiper arm in approximate park position onto

rear window wiper arm shaft and tighten securing nut -arrown AG. Volkswagen AG do
by hand.
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132
ht
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Clip cover -1- onto rear window wiper.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
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mer
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by wiper park position page 135 .guar

Adjust rear window
a
ed

3.3

wiper motor
3.3.1 Removing and installing rear window wiper motor, vehi

3.3.2 Removing and installing rear window wiper motor, vehi
cles with rear wing doors, page 134
3.3.1

wiper motor, vehicles with rear lid

AG. Volkswagen AG d
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b
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ise arm page 131 .
r
Remove rear window wiper
o
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sa
Unclip and remove scover
on wiper motor.
Removing:
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Remove hose -2- from window washer system.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Remove securing nuts -arrows-.

Carefully pull motor from rear lid.
Installing:

Check seal is seated correctly in opening of rear window. Mark

-1- on seal must align with mark -2- on rear window.
Caution
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Before inserting rear window wiper motor , moisten rear win

dow wiper arm shaft with lubricant polyethylene glycol.
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Prote
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Install rear window wiper arm page 131 .
133

3.3.2

wiper motor, vehicles with rear wing
doors

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Removing:
Remove rear window wiper arm page 131 .
Remove left rear wing door trim General body repairs, in

terior; Rep. gr. 70 ; Rear lid/rear wing door trims .
Remove the lock cylinder carrier and the left rear wing door
lock General body repairs, exterior; Rep. gr. 55 .
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 , moisten rear win

dow wiper arm shaft with lubricant polyethylene glycol.
Install rear window wiper arm page 131 .
134
AG.
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Carefully remove motor from rear wing door.
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Remove hose -2- from rear window washer system.
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3.4
Adjusting rear window wiper park posi

tion
3.4.1 Adjusting rear window wiper park position, vehicles with

rear lid, page 135
3.4.2 Adjusting rear window wiper park position, vehicles with
rear wing doors, page 135
3.4.1

tion, vehicles with rear lid

es, in part or in w
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Distance -a- between rear window wiper rubber and lower edge
of rear window must be 25 mm.
Adjust rear window wiper park position by moving rear window
wiper arm, if necessary.
Removing and installing rear window wiper arm page 131 .
Tighten threaded connection to specified torque page 129 .

tion, vehicles with rear wing doors
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Move rear window wiper to park position.
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AG.
Move rear window wiper to park position.
135

Distance -a- between rear window wiper rubber and edge of door
must be 25 mm.
Adjust rear window wiper park position by moving rear window
wiper arm, if necessary.
Removing and installing rear window wiper arm page 131 .
Tighten threaded connection to specified torque page 130 .
3.5

wiper blade
3.5.1 Removing and installing rear window wiper blade, vehi

cles with rear lid and joint-free rear window wiper, page 136
3.5.1

wiper blade, vehicles with rear lid and
joint-free rear window wiper
Note
On vehicles with rear lid, the standard rear window wiper blade
has been replaced by a joint-free rear window wiper blade.
Rear window wiper blades of that kind 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.
Switch off ignition and all electrical loads, and pull

key.
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Fold up rear window wiper arm -2-.
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Pull rear window wiper blade fastening element -1- out of rear
window wiper arm -2- -arrow-.
rrectness of i
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136
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Removing:

Remove rear window wiper blade fastening element -1- from
axis -2- of rear window wiper arm.
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Installing:
Push rear window wiper blade fastening element -1- onto axis
-2- of rear window wiper arm -3-.
Push rear window wiper blade fastening element into rear win
dow wiper arm until it engages.
Carefully fold rear window wiper arm back onto rear window.
Prote
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by
3.6.1
AG.
3.6.2 Renewing rear window wiper rubber, vehicles with rear

wing doors, without joint-free rear window wiper, page 138
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3.6.1 Removing and installing rear window wiper rubber, ve

hicles with rear lid and joint-free rear window wiper, page 137
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Renewing rear window wiper rubber
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3.6

wiper rubber, vehicles with rear lid and
joint-free rear window wiper
Note
On vehicles with rear lid, the standard wiper blade has been re
placed by a joint-free wiper blade.
Remove joint-free rear window wiper blade page 136 .
Check to see on which side the wiper rubber cannot be pushed
into the guide.
On the side that cannot be pushed into the guide, carefully
lever off the cap -1-.
137

Bend rear window wiper rubber stop -A- open using a suitable
screwdriver.
Replace wiper rubber.
Note
Ensure that wiper rubber blade is seating correctly in wiper rubber

blade guides.
Push wiper blade stop -A- back down using a suitable screw
driver until wiper rubber blade can no longer be moved in the
guide.
rrectness of i
t to the co
nform
spec
at
i
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in t
his
Fit new cap -1- and check it is seated securely.

Install rear window wiper blade page 136 .
Check wiper blade is working correctly.
Renewing rear window wiper rubber, ve

hicles with rear wing doors, without jointfree rear window wiper
Prote
cted
by
138
AG.
Remove rear window wiper blade.
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Removing:
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On enclosed side of wiper rubber, press steel strips and wiper
rubber together using suitable pliers.
Turn both steel strips and wiper rubber sideways out of upper
clip.
Pull both steel strips and wiper rubber out of wiper blade clips.
Installing:
Thread new wiper rubber into lower clips of wiper blade.
Guide both steel strips into the first groove of the wiper rubber
AG. Volkswagen AG d
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Press both steel strips and wiper rubber back together
using
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suitable pliers.
s
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Place both steel strips and wiper rubber in upper clip so that
lugs of clip engage on both sides in retaining grooves
-arrowof wiper rubber.
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139
Prote
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Rear window washer system
4.1 Assembly overview - rear window washer system,

page 140
4.2 Removing and installing rear window spray jet,
page 144
4.3 Adjusting spray jet for rear window washer system,
page 144
4.1

er system

cles with rear wing doors, page 142
4.1.1

er system, vehicles with rear lid
Note

equipment.
The rear window washer system function can be checked us

unit - J519- .
n AG. Volkswagen A
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and Fitting loca
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140
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wit

ing mode page 403 .
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Operating manual

1 - Connection piece
Interior wiring harness
point of separation to
rear lid wiring harness.
lines page 154
for rear window washer
system
lines page 154
3 - Spray jet for rear window
washer system
page 144 .
Adjusting page 144 .
4 - Hose
Hose repair
page 155
. Volkswagen AG
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5 - Filler pipe for
Vol washer fluid
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and installing
tho
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rrectness of i
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Removing and instal
auxiliary heater
page 120
Removing and instal

Connection to windscreen and rear window washer pump - V59 Overview of hose couplings for washer fluid lines page 154
8 - Windscreen and rear window washer pump - V59 Removing and installing, vehicles without auxiliary heater page 123
thi
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4. Rear window washer system
141
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4.1.2

er system, vehicles with rear wing doors
Note

equipment.
The rear window washer system function can be checked us

unit - J519- .
Current flow diagrams, Electrical fault finding and
Fitting loca
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Fault detection and fault
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ing mode page 403 .
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142
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display:
a
ss
ht
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Operating manual

Interior wiring harness
point of separation to
rear wing door wiring
harness.
lines page 154
for rear window washer
system
lines page 154
3 - Spray jet for rear window
washer system
page 144 .
Adjusting page 144 .
4 - Hose
Hose repair
page 155
5 - Filler pipe for washer fluid
reservoir
page 123 .
6
AG. Volkswagen AG d
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- Washer fluid reservoir ed b
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Removing and instal
h
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Connection to windscreen and rear window washer pump - V59 Overview of hose couplings for washer fluid lines page 154
rrectne
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auxiliary heater
page 120
Removing and instal
8 - Windscreen and rear window washer pump - V59 Removing and installing, vehicles without auxiliary heater page 123
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4. Rear window washer system
143
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4.2

spray jet
Removing:
Allow rear window wiper to adopt park position.
key.
Fold up cover of rear window wiper arm.
Pull spray jet out of rear window wiper arm shaft using suitable
pliers -arrow-.
Installing:
Push spray jet as far as stop into rear window wiper arm shaft,
ensuring that spray jet opening faces upwards.
Adjusting spray jet page 144
4.3
Adjusting spray jet for rear window

washer system
Note
tions.
then permitted.
es n
wage
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Adjusting rear window washer system spray jets Maintenance
;
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144

Headlight washer system
5.1 General description - headlight washer system,

page 145
5.2 Assembly overview - headlight washer system,
page 146
5.3 Removing and installing headlight washer system pump
V11 , page 147
5.4 Removing and installing spray jet pop-up cylinders, page
148
5.5 Removing and installing spray jet assembly, page 151
5.6 Adjusting headlight washer system spray jets, page 152
5.7 Bleeding headlight washer system, page 153
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General description -lkheadlight
washerdoes n
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The function of the headlight washer system can be checked
rrectness of i
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using the final control diagnosis of the onboard supply control

unit - J519- .
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Note
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tions
Operating manual
Every fifth time the windscreen washer system stalk is activated

the headlight washer system is also activated and headlights are
washed. Provided either dipped beam or main beam are switched
on and the windscreen washer system stalk is pulled for at least
1.5 seconds.
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Following installation work or on initial start-up of the headlight

washer system, the system must be bled to ensure proper oper
ation of the pop-up cylinders and spray jets page 153 .
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The active time of the headlight washer system can be variably

adjusted to between 0 and 12.75 seconds page 381 .
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5.1

ing mode page 403 .
5. Headlight washer system
145

5.2
Assembly overview - headlight washer

system
Note

different shape may be installed, depending on the vehicle equip
ment.
1 - Washer jet assembly with
washer jets
spray jet assembly
page 151
Adjusting spray jets
page 152
spray jet pop-up cylin
der, vehicles up to 2011
page 148
AG. Volkswagen AG d
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Removing and installing lkswagen
not
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spray jet pop-up cylind by Vo
ara
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2011 page 150
u
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3 - Hose
4 - Angled piece
5 - Y-piece
Connection to right
spray jet pop-up cylin
der
Distribution of wash wa
ter line to headlight
washer system spray
jets
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Removing and instal
auxiliary heater page 120
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Connection to left spray
jet pop-up cylinder
lines page 154
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AG.
Prote
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Connection to headlight washer system pump - V11 Overview of hose couplings for washer fluid lines page 154
9 - Headlight washer system pump - V11 Removing and installing, vehicles without auxiliary heater page 147
146

10 - Filler pipe for washer fluid reservoir
5.3
Removing and installing headlight

washer system pump - V11-
5.3.1 Removing and installing headlight washer system pump

V11 , vehicles without auxiliary heater, page 147
swagen Asystem
5.3.2 Removing and installing headlight
pump
n AG. Volkwasher
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V11 , vehicles with auxiliaryVheater,
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Removing:
key.
Unclip fog light trim, or remove right fog light page 243 .
Detach hose from connection pipe -3- of headlight washer
system pump -2-.
Unclip connection pipe -3- of headlight washer system pump
from washer fluid reservoir.
Pull headlight washer system pump -2- upwards -arrowout
Installing:
following:
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Release and disconnect connector -1-.
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atio
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wit
The headlight washer system pump - V11- is mounted on the

washer fluid reservoir in the right-hand wheel housing.
or
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washer
system pump - V11- , vehicles
ss
without auxiliary heater
es, in part or in w
l purpos
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5.3.1
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db
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r
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au

washer system pump - V11- , vehicles
with auxiliary heater
The headlight washer system pump - V11- is mounted on the

washer fluid reservoir in the right-hand wheel housing.
Removing:
key.
Caution

147

Unscrew bolts -2-.
Unscrew bolts -3- of right wheel housing (facing upwards).
Unscrew bolts -4- and -5- of right wheel housing.
Pull front bumper cover -1- on the right side out of catches of
guides on wing -arrows a- until the headlight washer system
pump is accessible.
Pull headlight washer system pump -6- upwards -arrowout
Installing:
AG. Volkswagen AG d
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or
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un
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ris washer
On completion of installation work, bleed headlight
ho
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system page 153 .
a
s
Removing and installing spray jet popup cylinders
5.4.1 Removing and installing spray jet pop-up cylinder, vehi

cles up to 2011, page 148
5.4.2 Removing and installing spray jet pop-up cylinders, ve
hicles as of 2011, page 150
key.
AG.
148
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Pull spray jets together with cover cap -1- out of bumper cover
to stop.
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Removing and installing spray jet popup cylinder, vehicles up to 2011
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5.4.1
AG. Volkswagen AG d
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10.2014
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Unclip cover cap -1- from mounting points -arrows- on spray

jet retainer.
Remove front bumper cover General body repairs, exterior;

Rep. gr. 63 ; Front bumper, up to 2011 .
rrectness of i
t to the co
nf
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spec
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wit
Push and hold down circlip -2- of hose connection -1- and pull
hose connection -1- off pop-up cylinder.
Remove securing bolts -3-.
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Unclip and remove pop-up cylinder -1- from bumper cover

-arrows-.
Installing:
following:
The pop-up spray jet cylinder hose must be attached to the re

taining clip on the bracket -arrow-.
Check headlight washer system spray jets and adjust if nec
essary page 152 .
149

5.4.2
Removing and installing spray jet popup cylinders, vehicles as of 2011

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.
Eject pop-up cylinder using only water pressure or air pressure.
A sticking pop-up cylinder can be brought back to full function
ality by ejecting it with water pressure or air pressure.
Removing:
Eject pop-up cylinder by activating headlight washer system,
and hold it in ejected position.
Unclip cover cap -1- from mounting points -arrows- on spray
jet retainer.
Note
On vehicles without auxiliary heater, the pop-up cylinders can
be removed without having to remove the bumper cover.
After the fog light on the relevant side has been removed, the
pop-up cylinder can be accessed through the aperture of the

fog light.
Vehicles without auxiliary heater:

. Volkswagen AG
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Unclip fog light cover, or remove fog light on
the
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Caution
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Vehicles with auxiliary heater:

Unscrew bolts -2-.
Unscrew bolts -3- of wheel housing (facing upwards) on the
respective side.
Unscrew bolts -4- and -5- of wheel housing on the respective
side.
Release catches at top of radiator grille
from lock carrier.
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Further removal is only possible
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Collect escaping fluid in a suitable container.
Push together locking mechanisms -arrows- on both sides,

and pull pop-up cylinder -2- in -direction of arrowout of mount
ing in bumper cover.
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Installing:
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Press and hold securing clip -arrow-, and pull hose connection
-1- off pop-up cylinder.
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Pull front bumper hcover
-1- on the respective side out of catchntee
or
or
ut
es of guides on awing
-arrows a- until the pop-up cylinder is
ac
s
s
accessible.
Install in the reverse order of removal. When doing this, note

the following:
AG.
Check cover cap is seated correctly on bumper cover.

system page 153 .
essary page 152 .
5.5
Removing and installing spray jet as

sembly
Removing:
key.
151

Pull spray jet together with cover cap -1- out of bumper cover
to stop.
Pull cover cap -1- off mountings -arrows- on spray jet assem
bly.
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Lift locking hooks -arrow- a little and
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Note
down onto the bumper cover can be adjusted using the detents
on the spray jet retainer.
rrectness of i
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The degree to which the cover cap of the spray jet is pulled
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If the spray jet assembly is not pulled in far enough, the cover
cap will not seat correctly.
If the spray jet assembly is pulled in too far, the cover cap and
the bumper cover could be pushed out of shape.
Push spray jet into pop-up cylinder until it locks in place.

Clip cover cap onto spray jet retainer and allow it to engage in
pop-up cylinder.
Check that cover cap is correctly seated on bumper cover.
If necessary, adjust seat of cover cap by pushing spray jet
assembly in higher or lower position on pop-up cylinder.
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essary page 152 .
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5.6
Adjusting headlight washer system

spray jets
Note
tions.
then permitted.

Adjusting headlight washer system spray jets Maintenance ;
152
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Installing:

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To guarantee soundaufunctioning
of pop-up cylinders and spray
c
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s
jets, the headlight washer
system must be bled following assem
Bleeding headlight washer system
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Top up washer fluid reservoir.
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Switch headlights ON.

Operate headlight washer system several times (3-5 times, 3
seconds each time).
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Repeat this bleeding procedure, if necessary, until the pop-up

cylinders and spray jets are functioning perfectly.
rrectness of i
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spec
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Start engine.
153
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Washer fluid line hose couplings
AG. Volkswagen AG d
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154
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General information for hose couplings for washer fluid lines is

Hose couplings for washer fluid lines .

Hose repair
AG. Volkswagen AG d
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General information for hose repair is available in the workshop

manual Electrical system, General information Electrical sys
tem, General information; Rep. gr. 92 ; Hose repair .
7. Hose repair
155
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Caddy 2004 , Caddy

2011
kswagen AG
AG. Vol
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Electrical system
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Lights,
bulbs, switches - exterior
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Rep. gr.94 - Lights, bulbs, switches - exterior
do
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Headlight
1.1 Assembly overview - headlight, page 158

1.2 Removing and installing headlight, page 166
1.3 Adjusting headlights, page 174
1.4 Adjusting headlight installation position, page 175
1.5 Removing and installing front turn signal bulb M5 / M7 , gen AG. Volkswagen AG d
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1.6 Removing and installing bulb for daytime running
ris light and
tho
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side light, page 185
a
ss
un
le
1.8 Removing and installing side light bulb M1 / M3 ,

page 188
1.9 Removing and installing main beam and dipped beam
bulb, page 191
1.10 Removing and installing dipped beam bulb M29 / M31 ,
page 193
1.11 Removing and installing main beam bulb M30 / M32 ,
page 196
1.12 Removing and installing bulb for static cornering light
M51/M52 , page 198
1.13 Removing and installing gas discharge lamp L13 / L14 ,
page 200
1.14 Removing and installing LED modules for daytime run
ning light and side light L176 / L177 , page 202
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1.17 Removing and installing dipped beam screen,

page 203
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1.16 Removing and installing swivel module position sensor

G475 / G474 , page 203
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1.15 Removing and installing dynamic cornering light control

motor V318 / V319 , page 202
rrectne
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t to the co
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form
spec
atio
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1.7 Removing and installing daytime running light and main

beam bulb, page 187
or
ac
1.18 Removing and installing gas discharge lamp control unit

J343 / J344 , page 203
1.19 Removing and installing output module for headlight
J667 / J668 , page 205
1.20 Removing and installing control unit for daytime running
light and side light J860 / J861 , page 207
1.21 Removing and installing cornering light and headlight
range control unit J745 , page 208
1.22 Coding cornering light and headlight range control unit
J745 , page 209
1.23 Headlight conversion for left-hand/right-hand traffic,
page 210
1.24 Removing and installing headlight range control actuator
V48 / V49 , page 225
1.25 Removing and installing front left vehicle level sender G78
, page 228
1.26 Removing and installing rear left vehicle level sender
G76 :, page 229
1.27 Installing repair kit for headlight housing, page 232
1. Headlight
157

1.1
AG. Volkswagen AG d
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Assembly overview - headlight

un
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1.1.1 Assembly overview - headlight with H7 bulb, vehicles up

to model year 2010, page 158
rrectness of i
t to the co
nform
spec
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1.1.2 Assembly overview - headlight with H4 bulb, vehicles as

of model year 2011, page 160
1.1.3 Assembly overview - headlight with H7 bulb, vehicles as
of model year 2011, page 161
1.1.4 Assembly overview - headlights with gas discharge
lamps and cornering lights, page 162
1.1.1
Assembly overview - headlight with H7

bulb, vehicles up to model year 2010
Note
and remove the ignition key.
When dealing with complaints, it is absolutely essential that

tions
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the function and operation of the lighting system are first un

derstood.
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Before working on headlights, always switch off the headlights
Operating manual
The onboard supply control unit has a self-diagnostic function,
which makes fault finding on headlights easier.
ing mode page 403 .
Note
After any measures which could affect the setting of the headlights, check the headlights and adjust if necessary
page 174
158

1 - Cover cap
2 - Securing bolts
For left headlight range
control motor - V48- or
right headlight range
control motor - V493 - Bleeder hose
To cover cap
Item 4 (page 159)
4 - Cover cap
5 - Bulb holder with grip ele
ment
For left headlight dipped
beam bulb - M29- or
right headlight dipped
beam bulb - M316 - Left headlight dipped beam
bulb - M29- or right headlight
dipped beam bulb - M31 Bulb H7U 12 V, 55 W
page 193 .
. Volkswagen AG
gen AG
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8 - Headlight
page 166 .
Correcting installation
position of headlight
page 175
Adjusting headlights page 174 .
Installing repair kit for headlight housing page 232
Converting headlights to drive on the left or the right page 210
ility
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wa
7 - Left headlight range control
olks
yV
b
actuator - V48- or right head
ed
ris
light range control actuator ho
t
V49au
ss
page 225 .
9 - Adjustment bush
Correcting installation position of headlight page 175
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12 - Securing bolts
5 Nm
On top of headlight
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11 - Bleeder hose
On headlight
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10 - Securing bolts
5 Nm
On base of headlight
13 - Left headlight main beam bulb - M30- or right headlight main beam bulb - M32 Bulb: H1, 12 V, 55 W
14 - Left side light bulb - M1- or right side light bulb - M3 Bulb: 12 V, W5W
1. Headlight
159

15 - Front left turn signal bulb - M5- or front right turn signal bulb - M7 Bulb: 12 V, PY 21W
16 - Bulb holder with grip element
For front left turn signal bulb - M5- or front right turn signal bulb - M7-
1.1.2
Assembly overview - headlight with H4 bulb, vehicles as of model year 2011
1 - Headlight
page 168 .
Securing bolt specified
torque (M8): 4 Nm
page 176
Adjusting headlights
page 174 .
Installing repair kit for
headlight housing
page 234
Converting headlights
to drive on the left or the
right page 212
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2 - Left sidelight bulb - M1- uand
th
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Right sidelight bulb - M3-ss,a Left
rrectness of i
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nform
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daytime running light bulb L174- and Right daytime run

ning light bulb - L175 Bulb 12V, 21/5W
page 185 .

ment
Left sidelight bulb - M1and Right sidelight bulb
- M3- , Left daytime run
ning light bulb - L174and Right daytime run
ning light bulb - L175-

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6 - Cover cap
do
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4 - Front left turn signal bulb M5- or front right turn signal
bulb - M7 Bulb: 12 V, PY 21W
7 - Left dipped beam bulb - M29- or right dipped beam bulb - M31- and left main beam bulb - M30- or right main
beam bulb - M32 Bulb H4 12V, 60/55W
AG.
160

8 - Left headlight range control actuator - V48- or right headlight range control actuator - V49 Removing actuator page 227 .
Checking actuator page 227 .
1.1.3
Assembly overview - headlight with H7 bulb, vehicles as of model year 2011
1 - Headlight
page 170 .
page 176
page 174 .
Installing repair kit for
headlight housing
page 238
Headlight conversion
for left-hand/right-hand
traffic page 219
6 - Cover cap
ole,
cial p
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5 - Left daytime running light

bulb - L174- or right daytime
running light bulb - L175- and
left main beam bulb - M30- or
right main beam bulb - M32 H15 bulb.
12 V, 15/55 W
page 187 .
AG.
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9 - Front left turn signal bulb - M5- or front right turn signal bulb - M7 Bulb, 12 V, PY21 W
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7 - Left headlight dipped beam bulb - M29- or right headlight dipped beam bulb - M31 H7 bulb
12 V, 55 W
rrectne
s
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t to the co
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spec
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4 - Cover cap
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ment
Left side light bulb - M1or right side light bulb M3-
un
le
2 - Left side light bulb - M1- or

right side light bulb - M3 Bulb: 12 V, 5 W
page 190 .
10 - Left headlight range control actuator - V48- or right headlight range control actuator - V49 Removing actuator page 227 .
1. Headlight
161

Checking actuator page 227 .
1.1.4
Assembly overview - headlights with

gas discharge lamps and cornering
lights
Note
The automatic headlight range control and cornering lights on

pe
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itte
d
headlights with gas discharge lamps is equipped with self-di

agnosis.
es, in part or in w
l purpos
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the function and operation of the lighting system are first un

derstood.
After measures that could influence the headlight setting,
check the headlight setting and, if necessary, correct the set

ting Maintenance ; Booklet ; Work descriptions .
tions
Operating manual
The headlights with gas discharge lamps and cornering lights
(AFS = Adaptive Front Lighting System) have a bi-xenon func
tion.
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With conventional xenon headlights, the gas discharge lamps

only generate the dipped beam. The bi-xenon features makes
it possible to generate both the dipped beam and the main beam
with one gas discharge lamp. To achieve this, an electrome
chanical adjuster ( left dip beam screen motor - V294- or right dip
beam screen motor - V295- ) uncovers the screened area of the
dipped beam on actuation of the main beam function, thus pro
ducing main beam light distribution.
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This means that with bi-xenon headlights the main beam is al

ways automatically adjusted together with the dipped beam.
The headlights with gas discharge lamps and cornering lights do
not have an additional main beam.
The cornering light system consists of the following functions:
Swivelling main and dipped beams (dynamic cornering lights):
at vehicle speeds in excess of 10 km/h and steering turned.
Cornering light bulb (static cornering light): when turning into
tight bends (bend radius < 500 m) or when turning a corner at
vehicle speeds of less than 50 km/h
The automatic headlight range control, the cornering lights and
onboard supply control systems feature self-diagnosis to facilitate
fault finding for headlights with gas discharge lamps.
For fault finding, use vehicle diagnosis, testing and information
system in Guided fault finding mode.
162
do
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rrectness of i
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a
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s
When dealing with complaints, it is absolutely essential that
ility
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es n
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Depending on equipment, the following functions can be adapted
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Adapting leaving home time
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94 ; Operation and safety notes for gas discharge lamps .
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The bulb failure warning

the headlight range control or the AFS (adaptive front lighting
system) malfunctions.
1. Headlight
163
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1 - Front end support part
2 - Securing bolts
M6 x 22
Specified torque: 4 Nm
3 - Headlight adapter
4 - Securing bolt
AM6 x 40 - S1, (included
with headlight).
5 - Cover cap
6 - Left gas discharge lamp L13- or right gas discharge
lamp - L14 Bi-xenon with gas dis
charge lamp starter unit
- N195 Type D3S, 42V/35W
page 200 .
7 - Screw cap
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turn signal bulb - M710 - Front left turn signal bulb - M5- or front right turn signal bulb - M7 Bulb, 12 V, PY21 W
11 - Headlight with LED module for daytime running light and side light
Converting headlights to drive on the left or the
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210
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Installing repair kit for headlight housing
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control unit - J745sa
Coding page 209 .
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13 - Front left vehicle level sender - G78 Removing and installing page 228 .
Securing bolt specified torque (M8): 9 Nm
14 - Rear left vehicle level sender - G76 Removing and installing page 229 .
Specified torque for securing nut: 5 Nm
15 - Control unit for left gas discharge lamp - J343- or control unit for right gas discharge lamp - J344 Removing and installing page 203 .
Securing bolt specified torque (M8): 1.3 Nm
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16 - Control unit for left daytime running light and side light - J860- or control unit for right daytime running light
and side light - J861 Removing and installing page 207 .
19 - Output module for left headlight - J667- or output module for right headlight - J668 Removing and installing page 205 .
Note
The cornering light and headlight

range control unit - J745- must be
recoded if a new output module for
headlight is installed page 209 .
Then subsequently perform the ba
sic setting of headlights Mainte
nance ; Booklet ; Descriptions of
work .
1. Headlight
165
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21 - Securing bolt
BM6 x 40 x 18 - S2.
22 - Checking left static cornering light - M51- or right static cornering light - M52 Bulb H7 12V, 55W
1.2
1.2.1 Removing and installing headlights, headlights with H7

bulb, vehicles up to model year 2010 , page 166
bulb, vehicles as of model year 2011, page 168
bulb, vehicles as of model year 2011, page 170

Note
There is no requirement to disconnect the battery earth strap.
Illustrations show removal and installation of the left headlight.
Removal and installation of the right headlight are carried out

in the same way.
If a headlight is removed, the alignment should always be
checked following installation page 174 .
Removing:
key.
Loosen and release the bolts and retaining hooks on the rel
evant side and pull bumper off bumper guide until all securing
bolts are accessible and the headlight can be pulled out of its
166
AG.
Removing and installing headlights,

headlights with H7 bulb, vehicles up to
model year 2010
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discharge lamps and cornering light, page 172
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20 - Adjustment sleeve (hollow-core


assembly aperture General body repairs, exterior; Rep. gr.
63 ; Front bumper, up to 2011 .
Using commercially available adhesive tape, mask off any po
tential contact areas between bumper cover and headlight to
avoid any scratches when removing and installing the head
light.
Unscrew securing bolts -arrows- and remove guide -1-.
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1. Headlight
167
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Remove headlight from vehicle.
Installing:
Installation is carried out in the reverse sequence. Observe the
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Check installation
position so that shut lines/gaps around
tho
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are
even.
s
If the shut lines/gaps around the headlight are uneven, the instal
lation position must be adjusted page 175 .
Note
If a headlight is removed or adjusted to fit more accurately to the

vehicle body, it must be aligned following such measures
page 174 .
1.2.2

headlights with H4 bulb, vehicles as of
model year 2011
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Torque wrench - V.A.G 1331ht

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Note

in the same way.
Removing:
key.
bolts are accessible and the headlight can be pulled out of its
168
rrectness of i
t to the co
nform
spec
at
i
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Check functions of headlight.

assembly aperture General body repairs, exterior; Rep. gr.
63 ; Front bumper, as of 2011 .
. Volkswagen AG
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-arrow-.
Remove securing bolt -arrow-.
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Loosen securing bolt -arrow-, do not unscrew completely.
1. Headlight
169
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Pull headlight out of body opening in a straight line towards

the front.
following:
Tighten all securing bolts and nuts to specified torques given
in assembly overview page 160 .
Check installation position of headlight so that shut lines/gaps
around headlight are even.
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model year 2011

Note

in the same way.
Removing:
key.
170
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1.2.3
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page 174 .
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respective side.
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es of guides on wing -arrows a- until all securing bolts for the
headlight are accessible and the headlight can be pulled out
of the assembly aperture.
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tential contact areas between bumper cover, wing and head
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headlight.
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In order to avoid scratches
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the headlight, mask off
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1. Headlight
171
rrectness of i
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Pull headlight out of body opening in a straight line towards
the front.
Installing:
following:
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Check installation position of headlight so that shut lines/gaps

around headlight are even.
AG.
Prote
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Note

page 174 .
1.2.4

headlights with gas discharge lamps
and cornering light
WARNING

mental pollution!
High voltage is supplied to the gas discharge bulbs. If they
are not handled properly they can cause serious or fatal
injuries.
If work on high-voltage components is to be performed af
ter a headlight has been removed (e.g change gas dis
charge bulb), the battery earth strap must be disconnected
and the residual voltage in the headlight must be dis
charged before the headlight is removed.
bulbs Electrical System, General Information; Rep. gr.
94 ; Operation and safety notes for gas discharge bulbs .
172
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un
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in the same way.
Removing:
key.
Caution

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In order to avoid scratches on the surfaces when removing

the headlight, mask off the surrounding areas.
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tential contact areas between bumper cover, wing and head
light to avoid any scratches when removing and installing the
headlight.
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Unscrew bolts -2-.

respective side.
side.
Pull front bumper cover -1- on the respective side out of catch
es of guides on wing -arrows a- until all securing bolts for the
headlight are accessible and the headlight can be pulled out
of the assembly aperture.
1. Headlight
173

Release and disconnect connector -1-.
Loosen, but do not unscrew completely, securing bolt -2- at
rear of headlight.
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hole
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Remove three securing bolts -arrows-.
Remove headlight forwards out of body aperture.

Installing:

Prote
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Note

page 174 .
1.3
Adjusting headlight in Maintenance manual: Maintenance ;

Booklet ; Descriptions of work .
174
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Check installation position so that shut lines/gaps around

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page 162 .
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First tighten bolts -arrows- to specified torque page 162 .

1.4
Adjusting headlight installation position
1.4.1 Adjusting headlight installation position, headlight with

H7 bulb, vehicles up to model year 2010, page 175
1.4.2 Adjusting headlight installation position, headlight
. Volkswagen AG
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bulbs H4 and H7, vehicles as of model year 2011,
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1.4.3 Adjusting installation position of headlights,
headlights
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with gas discharge lamps and cornering
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Adjusting headlight installation position,

headlight with H7 bulb, vehicles up to
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If the shut lines/gaps around the headlight are uneven after in

stallation, the installation position must be adjusted.
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Note
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key.
bolts are accessible General body repairs, exterior; Rep.
gr. 63 ; Front bumper, up to 2011 .
Unscrew securing bolts -arrows- and remove guide -1-.
1. Headlight
175

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Loosen -arrows- at bottom of headlight.
Adjust shut lines/flushness to body by pushing in or pulling out

alignment bush -arrow-.
Check headlight installation position to ensure gaps are even;

correct if necessary.
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Fit bumper cover in reverse sequence.

page 174 .
1.4.2
Adjusting headlight installation position,

headlight with bulbs H4 and H7, vehicles
as of model year 2011
176
do
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rrectness of i
t to the co
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spec
a
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Loosen bolts -arrows- at top of headlight.

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If the shut lines/gaps around the headlight are uneven after in

stallation, the installation position must be adjusted.
key.
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Loosen securing bolt -arrow-.
rrectne
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atio
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Note
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Loosen securing bolt -arrow-.
1. Headlight
177

alignment bush -arrow- on headlight.
Tighten threaded connections to specified torques given in
es n
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Check headlight installation position to ensure gaps hare
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Note
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page 174 .
1.4.3
Adjusting installation position of head

lights, headlights with gas discharge
lamps and cornering lights
The diagrams show the adjustment of the installation position
for the left headlight. The adjustment of the right headlight fol
lows the same principle.
key.
Loosen, but do not unscrew completely, securing bolt -2- at
rear of headlight.
178
AG.
installation, the installation position must be adjusted.
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Tighten bolt -2- at rear of headlight to specified torque

page 162 .
Check headlight setting and adjust headlight as necessary

page 174 .
1. Headlight
179

1.5
Removing and installing front turn signal

bulb -M5- / -M7-
lkswag
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1.5.1 Removing and installing front turn
signal
M5
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headlights with H7 bulb, vehicles as of model year 2011,
page 183
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1.5.2 Removing and installing
front turn signal bulb M5 / M7 ,
au
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headlights with H4 bulb, vehicles
as of model year 2011,
page 181
1.5.4 Removing and installing front turn signal bulb M5 / M7 ,

headlights with gas discharge lamps and cornering lights,
page 184
1.5.1

bulb -M5- / -M7- , headlights with H7
Note
Removing and installing the bulbs is possible when the head

The diagrams show renewal of the front left turn signal bulb Prote
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AG.
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out in the same way.
key.
Release catch -1- in -direction of arrow- and remove cap -2-.
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-direction of arrow- and remove bulb holder from headlight.
180
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Installing:
Caution
When installing, make sure cover is correctly seated. The in

gress of water will lead to permanent damage to the headlight.
Do not touch bulb glass when installing a bulb. Fingers leave
traces of grease on the glass, which evaporate when the bulb
is switched on and cause the glass to cloud over.
do
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headlight.
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Note
When engaging cap, do not press against retaining lug -1- as this
can break off.
Apply pressure on cover cap -arrows- until it is heard to en
gage.
Check function of headlight.
Checking and, if necessary, adjusting headlight setting
page 174 .
1.5.2

bulb, vehicles as of model year 2011
Note
light is installed.
The diagrams show renewal of the front left turn signal bulb -
M5- .
1. Headlight
181

Removing:
key.
Turn grip element -A- in -direction of arrow-.
Press bulb -1- into grip -2-, turn it to left and pull it out in a
straight line.
Installing:
Prote
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Make sure seal is correctly seated when grip element is instal

led. The ingress of water will lead to permanent damage to the
headlight.
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page 174 .
182
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Caution
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Note
light is installed.
M5- .
Removing:
key.
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183
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headlight.

page 174 .
r
fo
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bulb -M5- / -M7- , headlights with gas
discharge lamps and cornering lights
Prote
cted
by
light is installed.
M5- .
Removing:
Switch off ignition and all electrical consumers, and remove
ignition key.
Turn bulb holder together with front turn signal bulb in
-direction of arrow- and remove from headlight.
184
AG.
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Installing:
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Press bulb -1- into grip -2-, turn it to

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Push front turn signal bulb -2- into grip -1-, turn it towards left
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Installing:
Caution

headlight.
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Removing and installing bulb for day

time running light and side light
rrectness of i
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1.6
1.6.1 Removing and installing bulb for daytime running light

and side light, headlights with H4 bulb, vehicles as of model year
2011, page 185
1.6.1
Removing and installing bulb for day

time running light and side light, head
lights with H4 bulb, vehicles as of model
year 2011
Note
light is installed.
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The side light bulb also functions as the daytime running light.
The illustrations show the renewal of the left side light bulb agen
lksw
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M1- / left daytime running light bulb - L174- .

AG.
The renewal of the right side light bulb - M3- / right daytime
running light bulb - L175- is carried out in the same way.
Removing:
key.
1. Headlight
185
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headlight.
page 174 .
186
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Caution
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Installing:
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Side light bulb / daytime running light bulb : 12 V, 21/5 W
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ning light and main beam bulb
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1.7
1.7.1 Removing and installing daytime running light and main

beam bulb, headlights with H7 bulb, vehicles as of model year
2011, page 187
1.7.1
Note
Removing and installing daytime run

ning light and main beam bulb, head
year 2011
The main beam bulb also functions as the daytime running
beam bulb - M30- / left daytime running light bulb - L174- .

Prote
cted
by
The renewal of the right headlight main beam bulb - M32- /
AG.
right daytime running light bulb - L175- is carried out in the

same way.
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The illustrations show the renewal of the left headlight main
ht
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light.
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light is installed.
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Removing:
key.
Remove protective cap -arrow-.
1. Headlight
187

Unscrew bulb holder -1- in -direction of arrow-.
Remove bulb from reflector.
Headlight main beam bulb / daytime running light bulb : 12
V, 15/55 W
Installing:
After inserting bulb into reflector, turn it clockwise as far as
stop. This ensures proper engagement of the bulb as well as
a proper electrical connection.
Caution

page 174 .
1.8
Removing and installing side light bulb M1- / -M3-
1.8.1 Removing and installing side light bulb M1 / M3 , head

lights with H7 bulb, vehicles up to model year 2010, page 188
1.8.2 Removing and installing side light bulb M1 / M3 , head
wagen AG
Volks2011,
.year
page
190
gen AG
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Removing
installing side light bulb
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M1- / a-M3, headlights with H7 bulb,
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1.8.1
light is installed.
The diagrams show renewal of the left side light bulb - M1- .
The renewal of the right side light bulb - M3- is carried out in
the same way.
Removing:
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188
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Note

Pull bulb holder -1- with side light bulb in -direction of arrowout of reflector.
Pull side light bulb -2- in -direction of arrow- straight out of bulb
holder -1-.
Side light bulb : 12 V, W 5 W
Installing:
Caution
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When installing,isemake
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t
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headlight.
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1. Headlight
189
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Note
can break off.
gage.
page 174 .
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Note
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Removing and installing side light bulb M1- / -M3- , headlights

with H7 bulb,
ss
vehicles as of model year 2011
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1.8.2
light is installed.
The diagrams show renewal of the left side light bulb - M1- .
The renewal of the right side light bulb - M3- is carried out in
the same way.
Removing:
key.
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190
thi
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Pull grip element -A- together with bulb holder out of reflector.

Pull -side light bulb- out of holder -2-.
Side light bulb : 12 V, W 5 W
Installing:
Caution

wagen AG headlight setting
olksadjusting
Checking and, if necessary,
en AG. V
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page 174 . olkswag
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Removing and installing main beam and

dipped beam bulb
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1.9.1 Removing and installing main beam and dipped beam

bulb, headlights with H4 bulb, vehicles as of model year 2011,
page 191
Removing and installing main beam and

dipped beam bulb, headlights with H4
Note
light is installed.
For reasons of clarity, the headlight is shown removed in the
following illustrations.
The dipped beam bulb also functions as the main beam.
do
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The illustrations show the renewal of the left headlight dipped
beam bulb - M29- / left headlight main beam bulb - M30- .

ht
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The renewal of the right headlight dipped beam bulb - M31- /
right headlight main beam bulb - M32- is carried out in the

same way.
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Removing:
key.
1. Headlight
191

rrectness of i
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Release and disconnect connector on bulb -arrow-.
Caution
Make sure cover cap is correctly seated when installing. The

ingress of water will lead to permanent damage to the head
light.
page 174 .
192
AG.
Installing:
agen
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Prote
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Headlight dipped beam bulb / headlight dipped beam bulb : H4,

12 V, 60/55 W
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Remove securing bolts -arrows- and fold back.
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Removing and installing dipped beam

bulb -M29- / -M31-
rrectness of i
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1.10
1.10.1 Removing and installing dipped beam bulb M29 / M31 ,

headlights with H7 bulb, vehicles up to model year 2010,
page 193
1.10.2 Removing and installing dipped beam bulb M29 / M31 ,
headlights with H7 bulb, vehicles as of model year 2011,
page 195

Note

c
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The diagrams show renewal of the left headlight dipped beam

Prote
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by
carried out in the same way.
AG.
The renewal of the right headlight dipped beam bulb - M31- is
agen
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bulb - M29- .
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light is installed.
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1.10.1
Removing:
key.
Push wire shackle to one side -1- in -direction of arrow-.
Take cover cap -2- out through recesses in side of headlight.
Turn bulb holder by grip element -1- in -direction of arrow- and

remove from headlight.
1. Headlight
193

Pull dipped beam bulb -2- in -direction of arrow- straight out of
bulb holder -1-.
Headlight dipped beam bulb : H7U, 12V, 55W
Installing:
Caution

Fit dipped beam bulb into bulb holder.
Place bulb holder with dipped beam bulb in headlight and turn
bulb holder by grip element -1- in -direction of arrow-.
es, in part or in w
l purpos
hole
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Put cap -2- into recess -1- of headlight and push fully into po
sition.

page 174 .
AG.
Prote
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194
ht
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do
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Lock cap -2- in place by closed the wire shackle -1- in


1.10.2

Note
light is installed.
The diagrams show renewal of the left headlight dipped beam
bulb - M29- .
The renewal of the right headlight dipped beam bulb - M31- is
Removing:
key.
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Remove holder together with dipped beam bulb from head

light.
195
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Pull bulb -1-out of bulb holder -2- in -direction of arrow-.
Headlight dipped beam bulb : H7, 12 V, 55 W
Installing:
Caution
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page 174 .
1.11
Removing and installing main beam

bulb -M30- / -M32-
Removing and installing main beam

Prote
cted
by
light is installed.
The illustrations show the renewal of the left headlight main
beam bulb - M30- .
The renewal of the right headlight main beam bulb - M32- is
Removing:
key.
196
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1.11.1 Removing and installing main beam bulb M30 / M32 ,

headlights with H7 bulb, vehicles up to model year 2010,
page 196

Pull off connector -arrow-.
Press spring-type wire shackle -1- and release spring-type

wire shackle -direction of arrow-.
Take main beam headlight bulb -1- out of bulb holder.

Headlight main beam bulb : H1, 12 V, 55 W
AG. Volkswagen AG d
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Installing:


headlight.
rrectness of i
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1. Headlight
197
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Note
can break off.
gage.
page 174 .
1.12
Removing and installing bulb for static

cornering light - M51/M52-
1.12.1 Removing and installing bulb for static cornering light

M51/M52 , headlights with gas discharge lamps and cornering
lights, page 198
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G. Volkswagen AG d
Removing and installing bulbwafor
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light is installed.
The illustrations show the bulb replacement for the left static
cornering light - M51- .
Bulb replacement for the right static cornering light - M52- is
For reasons of clarity, the headlight is shown removed in the
Prote
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by
Note
Cornering light bulb -1- is clipped into reflector.
Initially, the connector is not disconnected when removing the
cornering light bulb .
Push connector -1- with bulb holder in -direction of arrow- until

bulb feels loose.
198
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Pull cover -2- off.
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Removing:
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following illustrations. There is no requirement to remove the

headlight to replace the cornering light bulb .
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The static cornering light integrated in the headlight is automati

cally switched on when the turn signal lever is operated and the
vehicle turns and when turning into tight bends. The static cor
nering light only functions at speeds lower than 40 km/h when the
dipped beam is switched on.
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Grasp on connector and pull cornering light bulb out of reflec

tor as far as wiring allows.
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Pull cornering light bulb -1- in -direction of arrow- straight off

connector -2-.
Installing:
thi
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Bulb for cornering light : H7 12 V, 55 W

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Caution

Guide cornering light bulb into headlight housing.
Push cornering light bulb into reflector.
Cornering light bulb must engage audibly.
page 174 .
1. Headlight
199

1.13
Removing and installing gas discharge

lamp -L13- / -L14-
1.13.1 Removing and installing gas discharge lamp L13 / L14 ,

page 200
1.13.1

lamp -L13- / -L14- , headlights with gas
WARNING

mental pollution!
High voltage is supplied to the gas discharge bulbs. If they
are not handled properly they can cause serious or fatal
injuries.
If work on high-voltage components is to be performed
af
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en AG. V gasadis
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ter a headlight has been removed k(e.g
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Vol must be disconnected
charge bulb), the battery earth strap
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and the residual voltage inrithe
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t
charged before the headlight
is removed.
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The illustrations show the renewal of the left gas discharge
lamp - L13- .
Renewal of the right gas discharge lamp - L14- is analogous.

Left gas discharge lamp - L13- and right gas discharge lamp
- L14- can be checked by the final control diagnosis for the

onboard supply control unit - J519- page 386 .
Removing:

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Headlights with gas discharge lamps and cornering lights

page 172
200
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Note
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Turn cover cap -1- anti-clockwise and remove it.
Pull connector -arrow- downwards off gas discharge lamp

starter unit - N195- -1-.
Turn gas discharge lamp starter unit - N195- -1- in

-direction of arrow- and carefully remove it from reflector to
AG. Volkswagen AG d
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Gas discharge lamp -L13- / -L14- : D3S, 42V/35W
n
ise
tee
or
ac
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a
ss
Installing:
es, in part or in w
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Risk of damage to the headlight.
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Caution
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Do not touch the glass part of the bulb with bare fingers.
When the light bulb is switched on, the heat would vapor
ise 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 bulbs.
Make sure the housing cover is correctly seated when in
stalling. The ingress of water will lead to permanent dam
age to the headlight.

page 174 .
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201
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1.14
Removing and installing LED modules

for daytime running light and side light L176- / -L177-
1.14.1 Removing and installing LED modules for daytime run

ning light and side light L176 / L177 , headlights with gas dis
charge lamps and cornering lights, page 202
1.14.1
Removing and installing LED modules

for daytime running light and side light L176- / -L177- , headlights with gas dis
charge lamps and cornering lights
The left LED module for daytime running light and side light L176- and the right LED module for daytime running light and side
light - L177- are located inside the respective headlight. The LED
module cannot be renewed individually.
In the event of damage, the headlight must be renewed
page 172 .
1.15
Removing and installing dynamic cor

AG. Volkswagen AG d
nering light control motor -V318- / agen
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1.15.1
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1.15.1 Removing and installing dynamic cornering light
au control
ss and
motor V318 / V319 , headlights with gas discharge lamps
cornering lights, page 202
rrectness of i
t to the co
nform
spec
at
i
h re
o
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in t
his
Removing and installing dynamic cor

nering light control motor -V318- / V319- , headlights with gas discharge
lamps and cornering lights
The dynamic cornering light only functions at a speed above ap

prox. 10 km/h when the dipped beam is switched on.
The dynamic cornering light control motors are located inside the
headlights. They cannot be replaced individually.
page 172 .
AG.
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202
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If faulty, check wiring of dynamic cornering light control motor for

wiring defects and/or loose connections before renewing head
light.
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Note

1.16
Removing and installing swivel module

position sensor -G475- / -G474-
1.16.1 Removing and installing swivel module position sensor

G475 / G474 , headlights with gas discharge lamps and cornering
lights, page 203
1.16.1
Removing and installing swivel module

position sensor -G475- / -G474- , head
lights with gas discharge lamps and cor
nering lights
The swivel module position sensors are located inside the head
lights. The swivel module position sensors cannot be renewed or
adjusted individually.
page 172 .
1.17

screen
1.17.1 Removing and installing dipped beam screen, head

lights with gas discharge lamps and cornering lights, page 203
1.17.1
Removing andVoinstalling
dipped beam
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1.18

lamp control unit -J343- / -J344-
1.18.1 Removing and installing gas discharge lamp control unit

J343 / J344 , headlights with gas discharge lamps and cornering
lights, page 203
1.18.1

lamp control unit -J343- / -J344- , head
lights with gas discharge lamps and cor
nering lights
thi
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WARNING
rrectness of i
t to the co
nf
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spec
atio
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n in
wit
es, in part or in w
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page 172 .
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au beam screens are located inside the headlights.r aThey

The dipped
c
ss
screens cannot be replaced individually or adjusted.

mental pollution!
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It is essential that the battery earth cable is disconnected

before any work on the components of the gas discharge
headlight is performed. The components of the gas dis
charge headlight are marked with a yellow high-voltage
symbol.
1. Headlight
203
AG.

Note
The gas discharge lamp control unit is installed on the under
side of the respective headlight housing.
The illustrations show how to remove and install the left gas
discharge lamp control unit - J343- .
Removal and installation of the right gas discharge lamp con
trol unit - J344- are analogous.
Removing:
ignition key.
Remove headlight page 172 .
Unscrew the three securing bolts -arrows-.
Carefully pull gas discharge lamp control unit -1- straight out
of headlight housing.
Release and disconnect electrical connectors -arrows- and

remove gas discharge lamp control unit -1-.
Installing:
Note
The cornering light and headlight range control unit - J745- must
be recoded if a new gas discharge lamp control unit is installed
page 209 . Then subsequently perform the basic setting of
headlights Maintenance ; Booklet ; Descriptions of work .
Tighten securing bolts to torque specified in assembly over
view page 162 .
Check headlight setting and adjust headlight if necessary
Maintenance ; Booklet ; Descriptions of work
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204
rrectness of i
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nf
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spec
atio
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wit
Make sure seal is correctly seated when installing the gas dis
charge lamp control unit. The ingress of water will lead to
permanent damage to the headlight.
thi
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es, in part or in w
l purpos
hole
ercia
, is n
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Caution
ility
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o of removal. When doings this,
Install in the reverse border
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following:
ir se
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ss

1.19
Removing and installing output module

for headlight -J667- / -J668-
1.19.1 Removing and installing output module for headlight

J667 / J668 , headlights with gas discharge lamps and cornering
lights, page 205
1.19.1
Removing and installing output module

for headlight -J667- / -J668- , headlights
lights
WARNING
AG. Volkswagen AG d
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Observe operation and safety notes for gas
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rrectness of i
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Note
es, in part or in w
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before any work on the components of the gas discharge
headlight is performed. The components of the gas dis
charge headlight are marked with a yellow high-voltage
symbol.
The output module for headlight is installed on the side of the
respective headlight housing.
The illustrations show how to remove and install the left output
module for headlight - J667- .
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Removing:
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light - J668- are analogous.
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Removal and installation of the right output module for head
1. Headlight
205

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rrectness of i
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com
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rm
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d
When power output module for headlight is pulled off from head
light housing, electrical connectors are simultaneously discon
nected.
Pull output module for headlight straight off headlight housing.
Installing:

Check seal between output module and headlight for damage.
Caution
AG.
206
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view page 162 .
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The cornering light and headlight range control unit - J745- must
be recoded if a new output module for headlight is installed
page 209 . Then subsequently perform the basic setting of
headlights Maintenance ; Booklet ; Descriptions of work .
do
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Note
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Make sure cover seal is correctly seated when installing the

headlight power module . The ingress of water will lead to per
manent damage to the headlight.

1.20
Removing and installing control unit for

daytime running light and side light J860- / -J861-
1.20.1 Removing and installing control unit for daytime running

light and side light J860 / J861 , headlights with gas discharge
lamps and cornering lights, page 207
1.20.1
Removing and installing control unit for

daytime running light and side light J860- / -J861- , headlights with gas dis
WARNING

mental pollution!
ra
c
The control unit for daytime running light and side light is in
stalled on the underside of the respective headlight housing.
The illustrations show how to remove and install the left control
unit for daytime running light and side light - J860- .
Removal and installation of the right control unit for daytime
running light and side light - J861- are analogous.
Removing:

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Carefully pull control unit for daytime running light and side
light straight off headlight housing.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
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AG. Volkswagen AG d
before any work on the components of the gaswdischarge
agen
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headlight is performed. The components yofVothe
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charge headlight are marked with a yellow
high-voltage
e
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symbol.
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1. Headlight
207
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Release -arrow- and disconnect connector -1-.
Installing:
Install in the reverse order of removal observing the following:
Check seal between control unit and headlight for damage.
Caution
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Make sure seal is correctlyeseated

the control
swageninstalling
AG. Volkwhen
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ag nand side light.AThe
e
w
unit for daytime running
light
ingress
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s
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ter will lead to permanent
damage to the headlight.t guara
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view page 162 .
1.21
rrectne
s
s
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spec
atio
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i
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thi
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Headlight range control unit must be recoded if a new control unit

for daytime running light and side light - J745- is installed
page 209 . Then perform the basic setting of headlights Main
tenance ; Booklet ; Descriptions of work .
Removing and installing cornering light

and headlight range control unit - J745-
1.21.1 Removing and installing cornering light and headlight

range control unit J745 , headlights with gas discharge lamps and
cornering lights, page 208
agen
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Prote
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Removing and installing cornering light

and headlight range control unit - J745- ,
and cornering lights
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1.21.1
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The cornering light and headlight range control unit - J745- is in

stalled underneath the dash panel near the centre console on
driver side.
Removing:
key.
Remove footwell trim on driver side General body repairs,
interior; Rep. gr. 69 ; Driver side footwell covers; Removing
and installing footwell trim .
Release locking bar -1- and pull connector -2- off cornering
light and headlight range control unit - J745- .
208

Unscrew securing bolts -arrows- and remove cornering light
and headlight range control unit - J745- from bracket.
Installing:
Note
After installing a new cornering light and headlight range control

unit - J745- , the control unit must be coded page 209 .
1.22
Coding cornering light and headlight

range control unit - J745- agen AG. Volkswagen AG do
w
olks
V
1.22.1 Coding cornering light and headlight
range control unit
by
ed
islamps
J745 , headlights with gas discharge
and cornering lights,
r
o
th
page 209
au
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le
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es, in part or in w
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ercia
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rrectness of i
t to the co
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a
t
i
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wit
thi
s
Coding cornering light and headlight

range control unit - J745- , headlights
lights
ility
ab
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1.22.1
ss
es n
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ua
ran
tee
or
ac

Body
Electrical system
Headlight range control -J745 Headlight range control functions
agen
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Prote
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Note
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Coding control unit
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If the cornering light and headlight range control unit - J745- has
to be coded, basic setting of the headlights must be performed
after coding Maintenance ; Booklet ; Descriptions of work .
1. Headlight
209

1.23
Headlight conversion for left-hand/righthand traffic
1.23.1 Headlight conversion for left-hand/right-hand traffic,

headlights with H7 bulb, vehicles up to model year 2010 ,
page 210
headlights with H4 bulb, vehicles as of model year 2011 ,
page 212
headlights with H7 bulb, vehicles as of model year 2011 ,
page 219
page 224
1.23.1
Headlight conversion for left-hand/righthand traffic, headlights with H7 bulb, ve

hicles up to model year 2010
Note
To avoid dazzling oncoming traffic with asymmetrical lights,
both headlights should be converted to the direction of traffic

(driving on the left or right) relevant to the country in which the
vehicle is being driven.
Conversion of the headlights is not designed as a permanent
conversion for other countries. It is only suitable sas
es n
wagae tourist
k
l
ot g
o
solution for a short stay abroad.
V
u
by
ara
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ed
ris
The corresponding headlight conversion
tho set consists of two
au
ss
or
ac
ility
ab
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an
pt
ce
un
le
sections of film.
Please note the different part numbers for the headlight con
The details right and left on the masking film always refer
to the direction of travel when looking forwards from inside the

vehicle.
Conversion of the headlights from right-hand to left-hand traf
fic and from left-hand to right-hand traffic is carried out in the

same way.
Turn light switch to 0 position.
Conversion from driving on right to driving on left:

Left headlight:
Clean headlight lens.
AG.
agen
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210
ht
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Remove release paper from masking film.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
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n
wit
i
n
thi
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or
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version sets from right to left-hand traffic and from left to righthand traffic.

Position contact edge -C- of application film at first continuous
line -A- on headlight lens.
n AG. Volkswagen A
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Position lower edge -Dofolkapplication film at lower edge
-Bgu of
by
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headlight lens.
nte
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Right headlight:
Position contact edge -C- of application film at first continuous
line -A- on headlight lens.
Position lower edge -D- of application film at lower edge -B- of
headlight lens.
Pull application film off headlight. Masking film cut-out remains
on headlight lens.
Remove any remaining adhesive using alcohol-based or al

ht
rig
py
Co
t.
cohol and water-based cleaning fluid. For example a cloth

soaked with isopropyl alcohol.
do
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n
Note
rrectness of i
t to the co
nform
spec
a
t
i
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wit
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es, in part or in w
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hole
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Pull application
off headlight. Masking film cut-out remains
ss
on headlight lens.
Prote
cted
by
c
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.
C
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Customers should be informed of how to remove residual ad

Conversion from driving on left to driving on right:
agen
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by
hesive after pulling off the masking section.
AG.
Left headlight:
Position contact edge -A- of application film at first continuous
line -B- on headlight lens.
Position lower edge -C- of application film at lower edge -D- of
headlight lens.
on headlight lens.
Note

Right headlight:
Align masking film as follows:
1. Headlight
211

Position contact edge -A- of application film at first continuous
line -B- on headlight lens.
Position lower edge -D- of application film at lower edge -C- of
headlight lens.
on headlight lens.
Note

1.23.2

hicles as of model year 2011
Note

conversion for other countries. It is only suitable as a tourist

n AG. V
The corresponding headlight conversion set consistsswof
two
age
un
le
hand traffic.
olkswagen AG
does
not
gu
ara
nte
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ra
c
ility
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olk
sections of film.
yV
db
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is
or headlight con
Please note the different part numbers forththe
u
a
version sets from right to left-hand traffic
and from left to rightss

vehicle.

same way.
AG.
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212
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Overview of application films for headlight conversion
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
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n
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i
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thi
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or
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a
itte
v
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p

1 - Application film for head
light conversion
Conversion from driving
on left to driving on right
For right headlight
for right headlight
page 217
light conversion
For left headlight
for left headlight
page 216
light conversion
on right to driving on left
For left headlight
for left headlight
page 213
light conversion
For right headlight
. Volkswagen AG
gen AG
does
on right to driving on leftVolkswa
not
gu
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b
ara
for right headlight edpage 214
nte
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ss
Left headlight:

Note
Take note of marking line on plastic lens of headlight. The appli

cation film must be applied along the marking line -1-.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Clean plastic lens of headlight.
thi
sd
o
cu
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en
es, in part or in w
l purpos
hole
ercia
, is n
m
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a
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iv
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ility
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1. Headlight
213
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Prote
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.
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Bond application film -1- along the dotted line -2- and over
corner point -3- onto plastic lens of headlight as shown in il
lustration.
ility
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ce
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
The illustration shows the headlight with masking film -1- after
conversion.
Caution
Risk of plastic erosion!

If solvent-based cleaners are used, the plastic lens of the
headlight could become damaged.
agen
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Prote
cted
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c
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.
C
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Note
Remove any adhesive residue using alcohol-based or diluted
alcohol-based cleaning fluids, for example with a cloth soaked

in isopropanol.
hesive after the masking film is pulled off.
Right headlight:
214
ht
rig
py
Co
t.
To remove any adhesive residue on the plastic headlight len

ses, use only alcohol-based cleaning agents or those with a
diluted alcohol mix (isopropanol).
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
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c
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AG. Volkswagen AG d
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th off plastic lens of headlight; masking
Pull application filmau-1ra
c
s
s plastic lens.
film -2- remains on

Note

lustration.
es n
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rrectness of i
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i
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es, in part or in w
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ility
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un
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Pull application film -1- off plastic lens of headlight; masking

film -2- remains on plastic lens.
1. Headlight
215
agen
lksw
Vo
by
AG.
Prote
cted
by
c
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p
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gh
t
.
C
op
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conversion.
Caution
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Note

in isopropanol.

Left headlight:

agen
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c
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.
C
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AG.
Prote
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lustration.
216
ht
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Note
do
c
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es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
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c
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erm
o
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a
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p
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f
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ility
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wage
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If solvent-based cleaners are used,
y Vthe plastic lens of the
ua
b
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ran
ir se
tee
o
h
t
or
u
ac
a
To remove any adhesive residue
on
the
plastic
headlight
len
ss

conversion.
Caution

Note
Remove any adhesive residue
using
or diluted
olkswalcohol-based
agen AG
en AG. V
does
ag
alcohol-based cleaning
fluids,
for example with
a cloth
soaked
ksw
not
Vol
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in isopropanol. ed b
ara
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is
or
th
or
Customersaushould
be informed of how to remove residual ead
a
hesive after
ss the masking film is pulled off.
Note

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
do
c
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en
es, in part or in w
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Right headlight:
1. Headlight
217
ht
rig
py
Co
t.
agen
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AG.
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C
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lustration.
AG. Volkswagen AG d
agen
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not
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V
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nte
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r
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h
t
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ra
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c
s
s
rrectness of i
t to the co
nform
spec
at
i
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o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
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n
ility
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conversion.

Prote
cted
by

in isopropanol.
218
AG.
Note
agen
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c
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t.
C
op
yi

do
c
um
en
ht
rig
py
Co
t.
Caution

1.23.3

Note

conversion for other countries. It is only suitable as a tourist

The corresponding headlight conversion set consists of two
sections of film.
Please note the different part numbers for the headlight con
version sets from right to left-hand traffic and from left to righthand traffic.

vehicle.

same way.
AG. Volkswagen AG d
agen
o
es n
ot g
ua
ran
tee
or
ac
w
olks
yV
b
ed
ris
ho
t
u
aheadlight
for
conversion
ss
r
fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
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o
c
erm
or
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a
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v
i
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p
un
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ility
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rig
py
Co
t.
Overview of application films
1. Headlight
219
agen
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by
AG.
Prote
cted
by
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gh
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.
C
op
yi

es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
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riv
du
p
or
nl
f
e
g
n

Position application film -1- at lower edge of grey surface on
headlight -arrows- and bond it on. At the same time, make sure
that application film is aligned against edge of plastic lens of
headlight next to body.
220
AG.
Left headlight:
agen
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Prote
cted
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c
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rig
ht
.
C
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ht
rig
py
Co
t.

light conversion
For right headlight
for right headlight page 223
do
c
um
en

light conversion
For left headlight
for left headlight
page 222
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

light conversion
For left headlight
for left headlight
page 220
AG. Volkswagen AG d
agen
oes
ksw
not
l
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b
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h
ut
ra
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s
s
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ce

light conversion
For right headlight
for right headlight
page 221

Pull application film -1- off plastic lens of headlight in
-direction of arrow-, ensuring that masking film -2- remains on
plastic lens of headlight.
conversion.
Caution

Note
Volkswagen AG
alcohol-based cleaning fluids, for example with agcloth
AG.soaked
does
a en
ksw
in isopropanol.
not
l
o
V
y
db
ise
Customers should be informed of how
or to remove residual ad
ss

ht
rig
py
Co
t.
r
fo
ng

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
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n
wit
i
n
thi
sd
o
c
um
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ole,
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is n
mer
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erm
or
e
t
a
itte
v
i
r
d
p
ility
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an
pt
ce
Right headlight:
un
le
th
hesive after the masking film is pulled
off.
au
gu
ara
nte
eo
ra
c
1. Headlight
221
agen
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by
AG.
Prote
cted
by
c
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rig
ht
.
C
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olkswagen AG
conversion.
en AG. V
Caution
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ss
does
not
gu
ara
nte
eo
ra
c
ility
ab
y li
an
pt
ce
wag
olks
yV
b
ed
ris
ho
t
au

Note
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his


in isopropanol.

AG.
222
agen
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Prote
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rig
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.
C
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ht
rig
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Co
t.
Left headlight:
do
c
um
en

conversion.
Caution

Note

in isopropanol.

Right headlight:
ility
ab
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an
pt
ce
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
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es n
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or
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rrectness of i
t to the co
nform
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at
i
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o
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in t
his

do
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Co
t.
agen
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1. Headlight
223
AG.
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C
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conversion.
Caution

Note
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
byor diluted
Remove any adhesive residue using alcohol-based
ara
d
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nte
ris cloth soaked
alcohol-based cleaning fluids, for example withhoa
eo
ut
ra
in isopropanol.
a
c
s
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
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erm
o
e
t
a
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du
p
or
nl
f
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n
ility
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Headlight conversion for left-hand/righthand traffic, headlights with gas dis

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
1.23.4
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.
Note
224
AG.

agen
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Prote
cted
by c
o
p
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gh
t.
C
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ht
rig
py
Co
t.

do
c
um
en
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 specifications.

Body
Electrical system
Headlight range control -J745 Headlight range control functions
Travel mode
1.24
Removing and installing headlight range

control actuator -V48- / -V49-
1.24.1 Removing and installing headlight range control motor

V48 / V49 , headlights with H7 bulb, vehicles up to model year
2010, page 225
V48 / V49 , headlights with H4 bulb, vehicles as of model year
2011, page 227
V48 / V49 , headlights with H7 bulb,
model year
ageof
n AG
AG. Volkswas
n vehicles
does
wage
2011, page 227
no
olks
t gu
a
V
by
1.24.1
Note
If control motor is renewed or if it is removed and then reinstalled,

the headlight adjustment must be checked and adjusted if nec
essary page 174 .
Removing:
key.
ht
rig
py
Co
t.
Push wire shackle to one side -1- in -direction of arrow-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

control motor -V48- / -V49- , headlights
with H7 bulb, vehicles up to model year
2010
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
1.24.5 Checking headlight range control motor, page 227
ility
ab
y li
an
pt
ce
ran
ed
1.24.4 Removing and
te
ris installing headlight range control motor
ho with gas discharge lamps and cornering e o
t
V48 / V49 , headlights
u
ra
a
c
lights, page 227ss
Prote
cted
by
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.
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yi
Take cover cap -2- out through recesses in side of headlight.
1. Headlight
225
agen
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by
AG.

Unscrew securing bolts -2- for headlight range control motor
-1-.
Push headlight range control motor -1- in -direction of arrowso that ball head of headlight range control motor can be pulled
downwards out of ball head cup in reflector.
Pull connector -1- off headlight range control motor -2-.

Remove headlight range control motor from headlight hous
ing.
Installing:
Install in the reverse
following:
un
le
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Note
The electrical connector of the headlight range control motor must

be connected prior to installation.
Connect electrical connector of headlight range control motor .
agen
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AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Fit cap -2- into recess -1- on headlight and push it fully into
position.
226
ht
rig
py
Co
t.
r
fo
ng
Carefully insert ball head of headlight range control motor -1in ball head cup -arrow-.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

ility
ab
y li
an
pt
ce
Caution
AG. Volkswagen AG d
agen
oes
ksw
no
l
o
yV
order of removal.
When
doing
this,
note
thet guar
b
d
an
e
tee
ris
ho
t
or
u
ac
a
ss

Lock cap -2- in place by closed the wire shackle -1- in
page 174 .
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1.24.2
The headlight range control motor cannot be removed.
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The headlight must be renewed if the headlight range control mo

tor is defective.
Checking headlight range control motor page 227 .
1.24.3

with H7 bulb, vehicles as of model year
2011
The headlight range control motor cannot be removed.

The headlight must be renewed if the headlight range control mo
tor is defective.
Checking headlight range control motor page 227 .
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The headlight range control motors -V48- / -V49- are located in

side the headlights. They cannot be replaced individually.
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1.24.4

page 172 .
Note
If faulty, check wiring of headlight range control motor for wiring

defects and/or loose connections before renewing headlight.
1.24.5
Checking headlight range control motor
The following procedure enables you to check left headlight range

control actuator - V48- or right headlight range control actuator V49- .
1. Headlight
227

olkswagen AG
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Using GoTo button, selectolkFunctions/component
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Electrical system

Electrical components, automatic headlight range control
Headlight range control motor
1.25
Removing and installing front left vehicle

level sender - G78-
1.25.1 Removing and installing front left vehicle level sender

G78 , headlights with gas discharge lamps and cornering lights,
page 228
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Note
The front left vehicle level sender - G78- is installed on the
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front axle.
If the vehicle level senders are renewed, basic setting of the

AG.
headlights must be performed afterwards Maintenance ;

Booklet ; Descriptions of work .

Removing:
key.
228
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Removing and installing front left vehicle

level sender - G78- , headlights with gas
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Automatic headlight range control

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Remove nut -5-.
Installing:
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Unscrew securing bolt -2-, and remove front left vehicle level
sender - G78- -3- with bracket.
rrectness of i
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Note
The lever of the vehicle level sender must face towards outer
side of vehicle.
The thread of the vehicle level sender must be screwed into
the front hole of suspension link -4-. The retaining lug of the
vehicle level sender must engage in the rear hole in order to
ensure the correct installation position.
Tighten upper securing bolt to 9 Nm.

Tighten new self-locking securing nut at bottom to 9 Nm.
Carry out basic setting of headlights Maintenance ; Booklet ;
Descriptions of work .
1.26
Removing and installing rear left vehicle

level sender - G76- :
1.26.1 Removing and installing rear left vehicle level sender

G76 , headlights with gas discharge lamps and cornering lights,
page 229
1.26.1
Removing and installing rear left vehicle

level sender - G76- , headlights with gas
Note
The rear left vehicle level sender - G76- is installed near the
left rear wheel.
2 new pop rivets are required for the installation of the rear left
vehicle level sender - G76- Electronic Parts Catalogue (ET

KA) .
If the vehicle level senders are removed and installed, basic
setting of the headlights must be performed afterwards

Maintenance ; Booklet ; Descriptions of work .
1. Headlight
229

Drill - VAS 5134-
es, in part or in w
l purpos
hole
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Pop rivet pliers - VAS 5072-
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Unscrew securing nut -2- and pull lower ball head out of se
curing clamp -1-.
Drill out heads of the 2 pop rivets -arrows-, and remove rear
left vehicle level sender - G76- -4-.
Remove remaining parts of pop rivets and all metal shavings
caused by drilling out the pop rivets.
If necessary, carry out corrosion protection measures on se
curing holes in body General information on paintwork; Rep.
gr. 00 ; Genuine products; Conservation .
Installing:
following:
Note
Connect and engage connector -3-.

Align securing clamp -1- with lower edge of outer shock ab
sorber tube, insert ball head mounting and tighten securing nut
to 5 Nm.
Carry out basic setting of headlights Maintenance ; Booklet ;
Descriptions of work .
rrectness of i
t to the co
nform
spec
at
i
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in t
his
Fit rear left vehicle level sender - G76- -4-, and rivet it to vehicle
body using 2 new pop rivets -arrows-.
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When installing rear leftrivehicle
level
sender
G76,
ensure
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lever and jointed rod uare
in position as illustrated. Otherwise the e or
ac
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rear left vehicle level
ss sender - G76- will supply incorrect data
1. Headlight
231
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1.27.1 Installing repair kit for headlight housing, headlights with

H7 bulb, vehicles up to model year 2010 , page 232
H4 bulb, vehicles as of model year 2011, page 234
H7 bulb, vehicles as of model year 2011, page 238
gas discharge lamps and cornering lights, page 242
1.27.1
Installing repair kit for headlight housing,

headlights with H7 bulb, vehicles up to
model year 2010
Note
r
fo
ng
using the repair kit for headlight housing. There is therefore no

need to renew the entire headlight.
Prote
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There are different repair kits for the left and right headlight
agen
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housing available Electronic Parts Catalogue .
AG.
Removal and installation are described for the left side. Re
moval and installation on the right side are carried out analo
gously.

Pneumatic sabre saw - VAS 1523 A-
key.
Remove headlight whose retaining tab is broken
page 168 .
232
ht
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If retaining tabs broke off the headlights, they can be renewed
rrectne
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Installing repair kit for headlight housing
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1.27
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Electrical system
- Edition 10.2014
ut
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Installing upper retaining tabs:
Note
The repair kit comprises 3 identical retaining tabs, each with
one securing bolt.
It is not necessary to install both retaining tabs if only one is
damaged.
Completely remove the area of the damaged retaining tab

shown in the diagram -arrows-.
rrectness of i
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nform
spec
at
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Insert the new retaining tab into the headlight housing until it
engages -arrows-.
Secure each of the retaining tabs with a bolt from the repair
kit.
Tighten securing bolts to specified torque of 3.5 Nm.
Installing lower retaining tabs:
Note
It is not necessary to install both retaining tabs if only one is
AG.
Completely remove the area of the damaged retaining tab

shown in the diagram -arrows-.
agen
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damaged.
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curing bolts.
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The repair kit comprises 2 retaining tabs, each with two se
1. Headlight
233

Insert the new retaining tab into the headlight housing until it
engages -arrows-.
Secure each of the retaining tabs with 2 bolts from the repair
kit.
Tighten securing bolts to specified torque of 3.5 Nm.
Install headlight and align it flush to body contour.
page 174 .
1.27.2

model year 2011
Note

un
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234
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Overview over headlight retaining tabs:
pe
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moval and installation on the right side are carried out in the
same way.
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There are different repair kits for the left and right
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1 - Headlight retaining tabs
-1 Renewing page 236 .
Specified torque for se
curing bolts: 3.5 Nm
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3 - Headlight housing -3 Removing page 168
un
le

1. Headlight
235

key.
page 168 .
Renewing headlight retaining tab -1-:
Cut off defect headlight retaining tab using a suitable tool, e.g.
pneumatic sabre saw - VAS 1523 A- . When doing this, always
wear protective goggles to protect the eyes. Grind down the
surface where tab was removed -arrow- with emery paper if
necessary and remove any burrs.
olkswagen AG
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Make sure that new headlight retaining tab is seated flush on se

curing points. Otherwise, a little more material must be removed
from the surface where the old headlight retaining tab was cut off.
AG.
Prote
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236
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Place new headlight retaining tab -1- over dedicated fastening

holes and secure it with supplied bolts -arrows- (specified tor
que: 3.5 Nm).
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que: 3.5 Nm).
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Place new headlight retaining tab -1a
c
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holes and secure it with supplied sbolts -arrows- (specified tor
rrectness of i
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que: 3.5 Nm).
1. Headlight
237

que: 3.5 Nm).
Push adjusting device of headlight housing -1- in

-direction of arrow- onto new headlight retaining tab.
page 174 .
1.27.3

headlights with H7 bulb, vehicles
as of
AG. Volkswagen AG d
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There are different repair kits for the left and right headlight
moval and installation on the right side are carried out in the
same way.
Overview over headlight retaining tabs:

Note
AG.
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238
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The overview shows the headlight retaining tabs of the H4 head

light. The headlight retaining tabs of the H7 headlight are only
slightly different to those of the H4 headlight.
rrectne
s
s
o
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i
t to the co
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form
spec
atio
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1. Headlight
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3 - Headlight housing -3 Removing page 170
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239

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page 168 .
240
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que: 3.5 Nm).
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que: 3.5 Nm).
rrectness of i
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his

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que: 3.5 Nm).
1. Headlight
241

que: 3.5 Nm).
Push adjusting device of headlight housing -1- in

-direction of arrow- onto new headlight retaining tab.
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page 174 .

and cornering lights
If both upper headlight retaining tabs -1-, the side retaining tab
-2- or the rearmost retaining tab -3- are damaged or have broken
off, they can be repaired by installing a repair kit. There is no need
to renew the entire headlight.
Note
would make installation of the repair kit unnecessary.
A repair kit is available for the headlight housing which can be
Prote
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by
AG.
242
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Installing the repair kit for the headlight housing on headlights with
gas discharge lamps and cornering lights is carried out in the
same way as on headlights with halogen bulbs as of 2011
page 234 or page 238 .
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used for the left or right headlight ETKA (Electronic Parts

Catalogue) .
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Check that there is no further damage to the headlight that

Fog lights
2.1 Removing and installing fog light, page 243

2.2 Removing and installing fog light bulb, page 245
2.3 Adjusting fog lights, page 245
2.1
Removing and installing fog light
2.1.1 Removing and installing fog light, vehicles up to model

year 2010, page 243
2.1.2 Removing and installing fog light, vehicles as of model
year 2011, page 244
2.1.1
Removing and installing fog light, vehi

cles up to model year 2010
Removing:
key.
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Installing:
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Pull fog light housing out of bumper.
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un
le
Unclip cover from catches -arrow-.

Tighten bolt for securing fog light to bumper cover to 1.5 Nm.
Check functioning of fog light.
Check fog light setting and adjust if necessary page 245 .
2. Fog lights
243

2.1.2
Removing and installing fog light, vehi

cles as of model year 2011
Removing:
Switch off ignition and all electrical loads, and pulln out
olkswagen AG
AG. Vignition
does
wage
key.
no
olks
Unclip cover from catches -arrow-. rised
o
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ra
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by
rrectness of i
t to the co
nf
o
r
m
spec
atio
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n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
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erm
or
e
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ce
th
au
ss
AG.
following:
Press fog light with tabs in -direction of arrow- into mountings

in bumper.
244
agen
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cted
by
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.
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Installing:
ht
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Pull fog light housing out of bumper.

Screw in securing bolt -1- and tighten it to 1.5 Nm.
Check functioning of fog light.
2.2
Removing and installing fog light bulb
Removing:
Removing fog light page
243
n AG. Volkswagen AG
age
ksw
does
n
ot
Vol
Turn bulb holder
it from
ua
by -1- in -direction of arrow- and gremove
ran
fog light. rised
te
tho
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pe
rm
itte
d
un
le
ility
ab
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pt
ce
u
ra
afor
The bulb
the fog light is permanently attached to the bulb
c
ss
holder and cannot be renewed separately.
The bulb for the fog light of type H11 (12 V, 55 W) was installed
in vehicles up to vehicle identification number 2K5 060 000.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Installing:
Caution
Check functions of fog light.
do
c
um
en
r
te o
iva
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rp
fo
g
n

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
All Caddy vehicles built after this have the HB4 bulb for the fog
light.

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Adjusting fog lights
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2.3
Adjusting spray jet in Maintenance manual Maintenance ;

Booklet ; Description of work
2. Fog lights
245
AG.
Prote
cted
by

Side turn signals
3.1 Removing and installing side turn signals, page 246

3.2 Removing and installing turn signal light bulb, page 247
3.1
Removing and installing side turn sig

nals
Note
The illustrations show removal and installation of the left turn
signal light
Removal and installation of the right turn signal light are anal
ogous.
Caution
Risk of damage when turn signal repeater is being removed!

It is only possible to remove turn signal repeater in one
direction, therefore great care must be taken during re
moval.
Attempting to lever out the light on the spring clip side by
force runs the risk of damaging the turn signal repeater or
the vehicle paintwork.
When seen from outside in installed condition, it is not
possible to tell on which side of the turn signal repeater
the bearing point is located and on which side the spring
clip is located.
ility
ab
y li
an
pt
ce
Removing:
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
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erm
or
e
t
a
itte
iv
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du
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f
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ng
AG. Volkswagen AG d
agen
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not
l
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by
ara
d
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is
r
o
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h
ut
ra
Locate spring clip by carefully pushing turn signal repeater
a
c
s
s
sideways.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
key.
Mask off the painted area on both sides of the turn signal.
Carefully press the turn signal light in the direction of the spring
clip -arrow- and, starting with the fixed anchor point, pull it out
of the body.
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AG.
Prote
cted
by c
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246

Pull holder together with glass base bulb -1- off bulb housing
-2- and remove bulb housing.
Installing:
following:
Fit holder together with glass base bulb -1- onto bulb housing
-2- so that retaining lugs -arrows- are opposite one another.
Insert bulb housing into body, starting with the spring clip -2-,
press in direction of spring clip -arrow- and secure it in body
with fixed anchor point -1-.
pe
rm
itte
d
AG. Volkswagen AG d
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s
s
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Removing and installing turn signal light

bulb
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
3.2
ility
ab
y li
an
pt
ce
un
le
Following installation, check whether turn signal light is func

tioning correctly.
Note
The illustrations show removal and installation of the bulb for
left turn signal - M18- .
Removal and installation of bulb for right turn signal - M19- are
analogous.
Removing:
do
c
um
en
ht
rig
py
Co
t.
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te o
iva
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fo
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key.
3. Side turn signals
247
agen
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Prote
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by
c
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Remove turn signal light page 246 .
Pull glass-base bulb -1- in a straight line out of bulb holder
-2-.
Bulb for turn signal repeater : 12 V, WY5W
Installing:
following:
e
wage
s no
t
ks
Vol
t
au
ss
ole,
cial p
is n
mer
m
ot p
o
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i
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p
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ht
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s
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o
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i
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form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
248
or
ac
ility
ab
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an
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ce
un
le
gu
by
ara
Following installation, check
whether turn signal light is func
ed
nte
tioning correctly. horis
e

Tail lights
4.1 Assembly overview - tail light, page 249

4.2 Removing and installing tail light, page 250
4.3 Removing and installing tail light bulb carrier, page 253
4.1
Assembly overview - tail light

Note
tions
Operating manual
The onboard supply control unit has a self-diagnosis function,
. Volkswagen AG
gen AG
does
which makes fault finding on the tail lights easier. Volkswa
not
y
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ht
rig
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Co
t.
rrectness of i
t to the co
nf
o
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m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
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or
e
t
a
itte
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e
For fault finding, use the systems described oin
ris chapter Vehicle
th Guided Fault Find
diagnosis, testing and information systemauin
ss
ing mode page 403 .
thi
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4. Tail lights
249
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AG.
Prote
cted
by

1 - Tail light housing
page 250
2 - Securing bolts
For tail light housing
Item 1 (page 250)
3.5 Nm
3 - Bulb carrier
page 253
4 - Left brake light bulb - M9- or
right brake light bulb - M10 12 V, P21 W
5 - Left reverse light bulb M16- or right reverse light bulb
- M17 12 V, P21 W
6 - Securing bolts
For bulb holder
Item 3 (page 250)
7 - Ball head stud
8 - Wiring harness
Only vehicles with rear
wing doors
9 - Trim
Note
On vehicles with rear wing doors,
the trim has a recess through

which the wiring harness passes
. Volkswagen AG
gen AG
does
Item 8 (page 250) to the rear Volkswa
not
gu
y
b
ara
wing door.
ed
nte
eo
ra
c
is
or
th
Removal and installation
au on ve
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
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f
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ng
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
10 - Connector
For tail light
ility
ab
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an
pt
ce
ss same as
hicles with rear lid is the
on vehicles with rear wing doors.
11 - Left tail light and rear fog lamp bulb - M41- or right tail light and rear fog lamp bulb - M42 12 V, P21 W, 4 W
12 - Rear left turn signal bulb - M6- or rear right turn signal bulb - M8 12 V, PY21 W
4.2
Removing and installing tail light
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by
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rig
ht
.
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thi
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250

Removing:
key.
Open rear lid or rear wing door.
Note
On vehicles with rear wing doors, the trim -2- has an opening
through which the wiring harness passes into the rear wing door.
Removal and installation on vehicles with rear lid is the same as
on vehicles with rear wing doors.
Unclip trim -2- from catches -arrows A- in tail light -3-.
AG. Volkswagen AG d
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c
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s
ht
rig
py
Co
t.
r
fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
Pull guide lugs -1- of trim out of slits -arrows B- of the tail light
and remove trim.
4. Tail lights
251
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Prote
cted
by
c
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rig
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.
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Pull mountings of tail light out of ball head studs in
Release and disconnect connector -1- and remove tail light

AG. Volkswagen AG d
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oes
-2- from vehicle.
no
lksw
t gu
ara
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ility
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pt
ce
Note
o
yV
db
ir se
ho
ut
a
ss
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
Installing:
If ball head stud has been removed (e.g. to facilitate body re
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
pairs), it must be screwed into body as far as it will go.
On vehicles with a rear lid, the rear lid remains open during
installation.
Close doors of vehicles with rear wing doors.
Push tail light together with mountings onto ball head studs in
Open doors of vehicles with rear wing doors.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
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.
C
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thi
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252

AG. Volkswagen AG d
agen
oes
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not
l
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by
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d
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nte
is
r
o
eo
h
ut
ra
a
c
s
s
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
Tighten securing bolts -arrows- to 3.5 Nm.
Insert guide lugs -1- of trim -2- into slots -arrows B- of tail light
-3-.
Note
On vehicles with rear wing doors, the wiring harness must be fed
through the recess in the trim -2-.
ht
rig
py
Co
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AG.
Prote
cted
by c
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C
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yi
4.3
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Press trims -2- into catches -arrows A- of tail light -3- until they
audibly engage.
Removing and installing tail light bulb

carrier
Removing:
Remove tail light page 250 .
4. Tail lights
253

Undo screws -arrows- and pull lamp carrier -1- out of tail light
-2-.
Installing:
ht
rig
py
Co
t.
agen
lksw
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by
AG.
Prote
cted
by c
o
p
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gh
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C
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thi
sd
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en
254
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s

Additional brake light
5.1 Removing and installing additional brake light,

page 255
5.2 Removing and installing additional brake light bulb/LEDs,
page 256
5.1
Removing and
installing additional
AG. Volkswagen AG d
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w
s
k
not
ol
brakeby Vlight
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ara
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e
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
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g
n
or
ac
ility
ab
y li
an
pt
ce
ed
ris
o
h
ut
Notess a
Depending on the type of vehicle, the additional brake light is
installed in either the rear lid or left rear wing door.

same for both versions.
tions
Operating manual
The onboard supply control unit has a self-diagnostic function,
which facilitates fault finding in respect of the additional brake
light.
ht
rig
py
Co
t.
c
o
p
yri
gh
t.
C
op
yi
Removing:
do
c
um
en

ing mode page 403 .
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Removal and installation of the additional brake light is the
agen
lksw
Vo
by
key.
AG.
Prote
cted
by
Open rear lid or left rear wing door.

Close rear lid or left rear wing door.
5. Additional brake light
255

. Volkswage
n AG d
AG
Pull additional brake light outkof
door
agen lid/left rear wing
oes until
swrear
not
l
o
gu
connector is accessible. by V
a
d
ise
ran
tee
or
ac
un
le
ility
ab
y li
an
pt
ce
or in -direction of arrow- and disconnect

Press retaining luguth-2a
connector -1-. ss
Installing:

Note
When installing additional brake light, make sure seal is correctly

seated.
5.2
Removing and installing additional

brake light bulb/LEDs
Note
The individual LEDs (light-emitting diodes) in the additional

c
o
p
yri
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t.
C
op
yi
brake lights are comprised in groups of 3 LEDs and are sup

plied with current in groups.
ht
rig
py
Co
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fo
ng
Failure of LEDs in additional brake lights
agen
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Prote
cted
by
Due to the failure of individual LEDs, the intact LEDs of the

AG.
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
additional brake must be renewed.
The LEDs in the additional brake light cannot be renewed indi

vidually. In the event of repairs, the additional brake light bulb M25- must be renewed as a complete unit page 255 .
256
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Take additional brake light out of rear lid/left rear wing door.

Number plate light
6.1 Removing and installing number plate light , page 257

6.2 Removing and installing bulb for number plate light, page
258
6.1
Removing and installing number plate

light
Note
Depending on the type of vehicle, the number plate light is
installed in either the rear lid or left rear wing door.
Removal and installation of the number plate light is the same
for both versions.
kswagFitting
en AG loca
n AG. Voland
Current flow diagrams, Electrical fault
gefinding
does
swa
k
not
l
o
tions
gu
yV
b
ed
ris
o
th
au
Operating manual
ara
nte
e
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

ing mode page 403 .
Removing:
key.
Unscrew securing bolts -arrows- for number plate light - X- .
Remove number plate light - X- .
Installing:
following:
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
The onboard supply control unit has a self-diagnosis function,

which makes fault finding on the number plate lights easier.
or
ac
ility
ab
y li
an
pt
ce
ss display:
Fault detection and fault
6. Number plate light
257
ht
rig
py
Co
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AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi

Note
A small silver coloured anti-dazzle strip -arrow- is fitted on scatter

lens of number plate light - X- . When installing the lens, always
make sure that the anti-dazzle strip faces the bumper. swagen AG. Volkswagen AG does
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
Removing and installing bulb for number

plate light
Removing:
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
6.2
not
gu
ara
nte
eo
ra
c
ility
ab
y li
an
pt
ce
k
Vol
by
d
e
ris
tho
u
a
ss
key.
Remove number plate light page 257 .
Press contact plate -1- in -direction of arrow- and remove bulb
-2- from bulb holder.
Bulb for number plate light - X- : festoon bulb, 12 V, C5W.
Installing:
agen
lksw
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by
AG.
Prote
cted
by
c
o
p
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.
C
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ht
rig
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Co
t.
258
thi
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Steering column switch module, ve

hicles up to model year 2010
7.1 General description - steering column switch module, ve

hicles up to model year 2010, page 259
7.2 Assembly overview - steering column switch module, ve
olkswagen AG
n AG-. V
7.3 Components of steering column switch module
removal
does
wage
s
k
not
l
o
and installation sequence, page 261
gu
yV
b
ed
ris column electronics con

7.4 Removing and installing steering
tho
u
trol unit J527 , page 262
sa
ara
nte
e
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
7.5 Removing and installing coil connector F350 , page 263
or
ac
7.6 Removing and installing steering angle sender G85 , page

265
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
7.7 Removing and installing turn signal switch E2 ,

page 266
7.8 Removing and installing windscreen wiper switch E , page
267
7.9 Removing and installing steering column switch module
base, page 269
7.10 Coding steering column electronics control unit ,
page 270
7.11 Steering column electronics control unit - final control
diagnosis, page 271
7.12 Basic setting of steering angle sensor , page 271
AG.
Prote
cted
by
The removal and installation of individual components of the

steering column switch module must be performed in a speci
fied sequence page 261 .
agen
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.
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Caution
ht
rig
py
Co
t.
General description - steering column

switch module, vehicles up to model
year 2010
thi
sd
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m
en
7.1
Note
If a new steering column electronics control unit - J527- is in
stalled, it must be coded page 270 .
In the event of faults in the steering column switch module, the
coding of the steering column electronics control unit - J527must be checked page 270 .
tions
The steering column electronics control unit - J527- is equipped
with self-diagnosis, which makes fault finding easier.
7. Steering column switch module, vehicles up to model year 2010
259

AG. Volkswagen AG d
agen
oes
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not
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ing mode page 403 .
ed
5 - Steering column electronics

control unit - J527 Observe removal and installation sequence! page 261
Coding page 270
Final control diagnosis page 271 .
6 - Coil connector - F350 Observe removal and installation sequence! page 261
7 - Steering angle sender - G85 Observe removal and installation sequence! page 261
Basic setting page 271
AG.
4 - Securing bolt
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3 - Windscreen wiper switch E Observe removal and

installation sequence!
page 261
page 267 .
thi
sd
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en
2 - Steering column switch

module base
Observe removal and
page 261
page 269 .
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
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erm
or
e
t
a
itte
iv
r
du
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f
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ng
ility
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1 - Turn signal switch

Observe removal and
page 261
page 266 .
The turn signal switch
comprises of the follow
ing components: turn
signal switch - E2- ,
headlight dipper and
flasher switch - E4- and,
if fitted with cruise con
trol system, cruise con
trol system switch - E45 The illustration shows
the turn signal switch
with no cruise control
system switch - E45-
260
nte
e
ris
ho
t
or
ac
Assembly overview - steering column
switch module, vehicles up to model
au
ss
year 2010
ht
rig
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Co
t.
7.2

7.3
Components of steering column switch

module - removal and installation se
quence
Caution
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
For removal of the complete steering column switch module, in

cluding base, the switch module is dismantled and the steering
lock housing is also removed. For assembly of the steering lock
housing, new shear bolts are required. Even if only one compo
nent of the steering column switch module is removed or re
newed, the sequence described as follows must always be
adhered to.
WARNING
Danger of the triggering of the airbag!

Improper action on airbag unit may result in the triggering
of the airbag!
agen
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cted
by
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rig
ht
.
C
op
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Remove driver airbag General body repairs, interior; Rep.

gr. 69 ; Airbag; Removing and installing driver airbag; Re
moving .
ht
rig
py
Co
t.
Observe safety precautions when working on airbag

General body repairs, interior; Rep. gr. 69 ; Airbag; Safety
precautions when working on airbag .
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
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t
a
itte
riv
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Removing:
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AG. Volkswagen AG d
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To disconnect and reconnect
the
battery,
the
procedure
de
nte
is
r
o
eo
h
scribed in the workshop
ut manual should be strictly adhered to
ra
a
c
s
page 3 .
s
AG.
Remove steering wheel Running gear, axles, steering; Rep.

gr. 48 ; Assembly overview - steering wheel; Removing and
installing steering wheel: Removing .
Remove steering column trim General body repairs, interior;
Rep. gr. 68 ; Compartments, covers and trims; Removing and
installing steering column trim .
Remove components of steering column switch module in follow
ing sequence:
Steering column electronics control unit - J527- page 262
Coil connector - F350- page 263
Steering angle sensor - G85- page 265
Turn signal switch - E2- page 266
Windscreen wiper switch - E- page 267
Steering column switch module base page 269
Installing:
261

7.4
Removing and installing steering col

umn electronics control unit - J527Note
After new control unit has been installed, it must be coded
page 270 .
coding of the control unit must be checked page 270 .

Caution

Torque wrench - V.A.G 1783-agen AG. Volkswagen AG do

Remove the following components in sequence (one after the
other):
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cted
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t.
262
rrectness of i
t to the co
nf
o
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m
spec
atio
h re
n in
wit
Removing:
thi
sd
o
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m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
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erm
or
e
t
a
itte
iv
r
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f
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ng
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au

Insert e.g. a piece of wire or a 2.5 mm drill bit -2- approx. 45 mm
into hole -arrow 1- in steering column electronics control unit
- J527- to release locking tab -arrow 2-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
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n
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AG. Volkswagen AG d
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ra
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Using a screwdriver, push against rear retaining clip -arrowof control unit for steering column electronics - J527- .
Carefully pull steering column electronics control unit - J527downwards off steering column switch module.
ht
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cted
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AG.
Pull locking bar -3- out of connector.
do
c
um
en
Release -arrow A- connector -1- and pull it off steering column

electronics control unit - J527- .
Release -arrow B- connector -2- and pull it off steering column
electronics control unit - J527- .
Installing:
following:
Note
When connecting connectors, ensure that none of the pins be

come bent and that the connectors audibly engage.
7.5
Removing and installing coil connector F350Caution

263

Removing:
other):
Remove steering column electronics control unit - J527 page 262 .
Note
Coil connector should not be moved out of central position during

removal and road wheels should be in straight-ahead position.
Slightly raise tabs -arrows- on coil connector -1-, and pull coil
connector towards rear and off steering column/steering
col
AG. Volkswagen AG d
agen
oes
umn switch module.
w
s
k
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l
Installing:
doing this, note the
ot g
ua
ran
tee
or
ac
Note
During installation of coil connector, coil connector must be in

central position and road wheels must be in straight-ahead po
sition.
AG.
Prote
cted
by
agen
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264
ht
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ng
The central position (depending on manufacturer) of the coil con

nector is shown in the following diagram:
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
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erm
or
e
t
a
itte
v
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d
p
un
le
ility
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ce
Install in the reverse order of

following:
o
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db
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ut
a
removal.
When
ss

The coloured strip (black rectangles) -arrow- must be located
in sight window -1-.
The coloured strip (yellow) -arrow- must be in sight windowswagen AG.
k
Vol
-1-.
by
If a new steering angle sensor - G85- in installed, this procedure

must be followed by a basic setting page 271 .
7.6
Removing and installing steering angle

sender - G85-
Assignment of fitting locations of steering angle sender:
Note
Prote
cted
by
2) Vehicles as of model year 2010
AG.
1) Vehicles up to model year 2009
x2)
agen
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x2)
No steering angle
sender installed
No steering angle
sender installed
x1)
c
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x1)
do
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en
Steering angle sender

on steering column
Steering angle sender
in steering rack
Vehicles with hy
draulic steering with
ESP
ht
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py
Co
t.
Vehicles with elec Vehicles with elec Vehicles with hy

tronic steering with tronic steering with draulic steering
out ESP
ESP
without ESP
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
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or
nl
f
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n
Note
ility
ab
y li
an
pt
ce
ed
ris
o
h
t
au
ss
Volkswagen AG
does
not
gu
ara
nte
eo
ra
c
On vehicles with hydraulic steering and without ESP, the
steering angle sender is no more installed as of 06.2007.
On vehicles with electronic steering as of model year 2010,
the steering angle sender is only installed in the steering rack.

Caution

Removing:
other):
265

Remove airbag coil connector and return ring with slip ring F138- page 263 .
Pull steering angle sender - G85- -1- towards rear -arrow- off
steering column switch module.
Installing:
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
7.7
ility
ab
y li
an
pt
ce
es n
wage
s
k
l
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o
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ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
Removing and installing turn signal

switch - E2-
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Note
The turn signal switch comprises of the following compo
nents: turn signal switch - E2- , headlight dipper and flasher

switch - E4- and, if fitted with cruise control system, cruise
control system switch - E45- .
For reasons of clarity, the steering column switch module is
shown in the removed state with cruise control system switch

- E45- in the illustration.
Prote
cted
by

other):
Remove steering angle sensor - G85- page 265
266
AG.
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Removing:
ht
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Co
t.

thi
sd
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cu
m
en
Caution

Release retaining clips -arrows- with a feeler gauge 1.0 mm
-1- and remove turn signal switch towards the rear.
Installing:
following:
Note
The turn signal switch should be heard to engage.
For reasons of clarity, the illustration shows the steering column

switch module in the removed state.
Caution

Removing:
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
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agen
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Co
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ng

other):
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Note
ility
ab
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an
pt
ce

wiper switch - Eun
le
7.8
AG. Volkswagen AG d
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is
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h
ut
ra
a
c
s
s

Remove turn signal switch - E2- page 266
267

Release retaining clips -arrows- with a feeler gauge 1.0 mm
-1- and remove windscreen/window washer switch - E- to
wards the rear.
Installing:
following:
Note
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
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cted
by
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ht
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Co
t.
268
do
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r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
The windscreen wiper switch - E- should be heard to engage.

7.9

umn switch module base
Note
To remove steering column switch module base -2-, shear bolts

of the steering lock housing must be drilled out. To reinstall, new
shear-head bolts -1- are required Parts catalogue (ETKA) .
Caution
Ensure that the components mounted on the carrier have

been removed before drilling out the shear-head bolts.
The drilling operation can cause swarf to penetrate the
adjacent components resulting in damage and/or mal
function!
Always observe the prescribed sequence when removing
components page 261 .
To disconnect and reconnect the battery, the procedure
described in the workshop manual should be strictly ad
hered to page 3 .
AG. Volkswagen AG d
agen
oes
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by
ara
d
e
nte
is
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o
The removal and installation of individual components
of
the
eo
h
ut in a speci
ra
a
steering column switch module must be performed
c
s
s
Caution
un
le
pe
rm
itte
d
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Removing:
ility
ab
y li
an
pt
ce

other):
r
te o
iva
r
rp
fo
g
n
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Prote
cted
by c
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p
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C
op
yi
Remove windscreen wiper switch - E- page 267
ht
rig
py
Co
t.
Remove turn signal switch - E2- page 266
do
c
um
en
AG.
269

Pull connector -arrow- off reader coil -3-.
The base can be removed once all the components secured to it
have been removed:
Drill out bolts -1- of steering lock housing -3-.
Note
Bolts M8 -1-, core diameter 6.8 mm

Pull steering lock housing and steering column switch module
base -2- towards rear off steering column.
Remove steering lock housing from steering column switch
module base.
Installing:
following:
Caution
Steering lock will be damaged if improperly fitted!

Failure to follow instructions will result in damage to the steer
ing lock when the shear-head bolts are tightened.
un
le
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
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not
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Before fitting the steering lock housing to the steering column,
yV
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ara
d
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nte
the ignition key must be turned in the lock cylinderorto
is the Ig
eo
h
nition ON position.
ut
ra
a
c
s
s
Push steering column switch module base -2- as far as pos

sible onto steering column.
Connect electrical connector -arrow- to reader coil -3-.
Bolt steering lock housing onto steering column using new
shear-head bolts -1-.
Tighten shear-head bolts -1- until bolt heads shear off.
Fit all components analogously in reverse order of removal.
r
fo
ng
Coding steering column electronics con

trol unit

Body
Electrical system
270
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
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yi
agen
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ht
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Co
t.
7.10
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Insert steering lock housing into steering column switch mod

ule base.

Steering wheel electronics
Steering wheel electronics functions
Coding steering wheel electronics control unit
7.11
Steering column electronics control unit

- final control diagnosis

Body
Electrical system
Steering wheel electronics final control diagnosis
7.12
Basic setting of steering angle sensor

Select Guided fault finding in vehicle
diagnostic tester .
. Volkswage
n AG
wage
n AG d
oe
s no
ks Functions/component
Using GoTo button,y select
and
t gu then
Vol
b
ara
d
the following menu
options
in
succession:
e
n
s
i
tee
or
ac
r
ho
ut
Running gear
sa
un
le
pe
rm
itte
d
01 - On Board Diagnostic capable systems Mark 60 / Mark 70

es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Anti-lock brake system ABS/EDL/TCS/ESP Mark 60
ility
ab
y li
an
pt
ce
Brake system
Functions
do
c
um
en
ht
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Co
t.
r
te o
iva
r
rp
fo
g
n
Basic setting of steering angle sensor - G85-
agen
lksw
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AG.
271
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi

Steering column switch module, ve

8.1 General description - steering column switch module, ve

hicles as of model year 2011, page 272
8.2 Assembly overview - steering column switch module, ve
8.3 Components of steering column switch module - removal
and installation sequence, page 274
8.4 Removing and installing steering column electronics con
trol unit J527 , page 275
8.5 Steering column combination switch E595 , page 278
8.6 Steering column switch module base, page 280
8.7 Coding steering column electronics control unit J527 ,
page 283
8.1
General description - steering column

switch module, vehicles as of model
year 2011
Caution
olkswagen AG
en AG. V
does
not
gu
ara
nte
eo
ra
c
t
au
ss
ility
ab
y li
an
pt
ce
un
le
wag
The removal and installation of individual Vcomponents
of the
olks
y
b
steering column switch module must beedperformed
in a speci
ris
ho
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Manufacturer Valeo: 3 bolts.

Manufacturer Kostal: 1 bolt at bottom and 2 fasteners at top.
Note
r
fo
ng
The steering column electronics control unit - J527- is equipped

with self-diagnosis, which is designed to simplify fault finding.
ing mode page 403 .
Prote
cted
by
AG.
272
agen
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by
c
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C
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ht
rig
py
Co
t.
Operating manual
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
The components of the steering column combination switch,

steering column electronics control unit and steering column
switch module base are installed as 2 different versions depend
ing on respective manufacturer (Valeo or Kostal). The visible
fastening of the steering column electronics control unit to the
steering column combination switch can be used to identify which
version is installed.

8.2
Assembly overview - steering column

switch module, vehicles as of model
year 2011
AG. Volkswagen
Note
AG do
es n
ot g
ua
ran
tee
or
ac
un
le
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
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d
p
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fo
ng
agen
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by
AG.
c
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p
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C
op
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2 - Steering column combina

tion switch - E595 Note removal and instal
lation sequence
page 274
(manufacturer Valeo)
page 278 .
(manufacturer Kostal)
page 279 .
ht
rig
py
Co
t.
1 - Steering column electronics

control unit - J527 Note removal and instal
lation sequence
page 274
page 275 .
page 276 .
Coding page 283 .
Specified torque of se
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
The components steering column electronics control unit - J527- ,

steering column combination switch - E595- and the steering col
umn switch module base are available as different versions de
pending on manufacturer (Valeo or Kostal). Illustration of
assembly overview shows Valeo version.
ility
ab
y li
an
pt
ce
agen
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Vol
y
b
ed
ris
o
h
t
au
ss
Prote
cted
by
3 - Steering column switch

module base
Note removal and instal
lation sequence
page 274
page 280 .
8. Steering column switch module, vehicles as of model year 2011
273

page 282 .
4 - Shear-head bolts
M8x20
Shear moment approx. 15 Nm
5 - Steering lock housing
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Removing and installing (manufacturer Kostal) page 282 .
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
6 - Ignition/starter switch and lock cylinder

8.3
Components of steering column switch

module - removal and installation se
quence
Caution

page 3 .
AG.

WARNING

of the airbag!
Remove steering wheel General body repairs, interior; Rep.
gr. 69 ; Airbag .
The components of the steering column module must be removed
in the following sequence:
Steering column combination switch - E595- page 278
274
agen
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Prote
cted
by
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py
rig
ht
.
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yi
Removing:
ht
rig
py
Co
t.
Even if only one component of the steering column switch module

is removed or renewed, the sequence described as follows must
always be adhered to.
do
c
um
en
For removal of the complete steering column switch module, in

cluding base, the switch module is dismantled and the steering
lock housing is also removed. For assembly of the steering lock
housing, new shear bolts are required.
Steering column electronics control unit - J527- page 275
base.
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
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l
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yV
Steering lock housing is removed and installed
together
with
steering
column
b
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Note removal and installationautsequence
page 274
ra
c
s
s
Removing and installing (manufacturer
Valeo) page 280 .

Steering column switch module base page 280 .
Installing:
8.4

umn electronics control unit - J527-
8.4.1 Removing and installing steering column electronics

control unit J527 , manufacturer Valeo, page 275
8.4.2 Removing and installing steering column electronics
control unit J527 , manufacturer Kostal, page 276

umn electronics control unit - J527- ,
manufacturer Valeo
Airbag coil connector and return ring with slip ring - F138 Steering angle sender - G85Note
stalled, the inserted transport protection must be removed

before installation.
ht
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Co
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The steering column electronics control unit - J527- comprises the

following components and cannot be dismantled:
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8.4.1
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Removing:
Caution

275

WARNING
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other):
gr. 69 ; Airbag .
Coil connector on steering column electronics control unit - J527must not be twisted from its centre position. The front wheels must
be in straight-ahead position.
AG.
Prote
cted
by
Unscrew the three securing bolts -arrows- and pull steering

column electronics control unit - J527- towards rear off steer
ing column switch module.
Installing:
Caution
Turn signal switch reset lever can break when control unit is
being installed.
Turn signal lever must be in 0 position when control unit is in
stalled so that reset lever is not extended.
Push steering column electronics control unit - J527- in a
straight line onto steering column switch module.
Screw in the three bolts for securing steering column elec
tronics control unit - J527- to steering column switch module
and tighten them to 1.5 Nm.
8.4.2

umn electronics control unit - J527- ,
manufacturer Kostal
The steering column electronics control unit - J527- comprises the

following components and cannot be dismantled:
276
agen
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Note
ht
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Depending on equipment level, release and disconnect con

nectors -1-, -2-, -3- and -4-.
rrectne
s
s
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f
i
t to the co
n
form
spec
atio
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of the airbag!

Airbag coil connector and return ring with slip ring - F138 Steering angle sender - G85Note
olkswagen AG
does
not
gu
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AG. V
stalled, the inserted transport protection must be removed
agen
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before installation.
by
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If a new steering column electronics control unit - J527tho
ility
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his
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Caution
do
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Removing:
ht
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Co
t.
WARNING

of the airbag!
other):
gr. 69 ; Airbag .
277

Depending on equipment level, release and disconnect con
nectors -1-, -2-, -3-, -4- and -5-.
Unscrew securing bolt -arrow B-.
Note
Coil connector for steering column electronics on steering column

electronics control unit - J527- must not be twisted from its centre
position. The front wheels must be in straight-ahead position.
Release both catches -arrows A- and pull steering column
electronics control unit - J527- towards rear and off steering
column switch module.
Installing:
Caution
Turn signal switch reset lever can break when control unit is
being installed.
Turn signal lever must be in 0 position when control unit is in
stalled so that reset lever is not extended.
Push steering column electronics control unit - J527- in a
straight line onto steering column switch module until it se
AG. Volkswagen AG d
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curely engages.
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db
Screw in bolt for securing steering columnriseelectronics
control
o
h
unit - J527- to steering column switch module
and tighten it to
t
u
a
1.5 Nm.
ss
es, in part or in w
l purpos
hole
ercia
, is n
m
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com
Steering column combination switch E595-
rrectness of i
t to the co
nform
spec
a
t
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wit
thi
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8.5
pe
rm
itte
d
8.5.1 Removing and installing steering column combination

switch E595 , manufacturer Valeo, page 278
8.5.2 Removing and installing steering column combination
switch E595 , manufacturer Kostal, page 279
8.5.1

umn combination switch - E595- , man
ufacturer Valeo
AG.
Prote
cted
by
agen
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278
c
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CCS switch - E45-
ht
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Windscreen wiper switch - E-
do
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Turn signal switch - E2-
r
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iva
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rp
fo
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n
Depending on equipment, the steering column combination

switch - E595- comprises the following components and cannot
be dismantled:

Caution

Removing:
gr. 69 ; Airbag .
Release both catches -arrows- and pull complete steering col
umn combination switch - E595- in a straight line and towards
rear off steering column switch module base.
Installing:
Push steering column combination switch - E595- in a straight
line onto guides on steering column switch module base until
it securely engages.
8.5.2

umn combination switch - E595- , man
ufacturer Kostal
Depending on equipment, theesteering

wagen AGcombination
n AG. Volkscolumn
does
wag following components
switch - E595- comprises
ksthe
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be dismantled:
ra
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or
h
Turn signalautswitch
- E2-
ss
un
le
pe
rm
itte
d
ility
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an
pt
ce
Windscreen wiper switch - E-
Caution

Removing:
gr. 69 ; Airbag .
do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
CCS switch - E45-
agen
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by
279
AG.
Prote
cted
by
c
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rig
ht
.
C
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Unscrew securing bolt -arrow- and pull complete steering col
umn combination switch - E595- -1- in a straight line and
towards rear off steering column switch module base.
Installing:
line onto guides on steering column switch module base.
Screw in securing bolt -arrow-.
8.6
Steering column switch module base
8.6.1 Removing and installing steering column switch module

base, manufacturer Valeo, page 280
8.6.2 Removing and installing steering column switch module
base, manufacturer Kostal, page 282
8.6.1

umn switch module base, manufacturer
Valeo
Note

-1- of the steering lock housing must be drilled out. New shearhead bolts are required for subsequent installation Electronics
parts catalogue (ETKA) .
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
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f
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AG. Volkswagen AG d
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Prote
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by
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thi
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280
ht
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Co
t.
rrectness of i
t to the co
nf
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m
spec
atio
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n in
wit
Angle hand drill

Caution
Ensure that all the components mounted on the base have

function!
The removal and installation of individual components of
the steering column switch module must be performed in
a specified sequence page 274 .
hered to page 3 .
Removing:
Remove all components attached to base in prescribed se
quence page 274 .
The carrier can be removed once all the components mounted to
it have been removed:
Drill out shear-head bolts -1- of steering lock housing -3-.
Note
Bolts M8 -1-, core diameter 6.8 mm
AG. Volkswagen AG d
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Pull steering lock housing -3- and steering column switch

module base -2- towards rear off steering column.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Installing:
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com

module base.
Insert steering lock housing -3- into steering column switch

module base -2-.
line onto steering column switch module base until it securely
engages.
Push pre-assembled unit consisting of steering lock housing,
steering column switch module base and steering column
combination switch - E595- as far as stop onto steering column
and align it with threaded holes.
Tighten new shear-head bolts -1- until bolt heads shear off.
ht
rig
py
Co
t.
do
c
um
en
r
te o
iva
r
rp
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Secure steering lock housing -3- to steering column using new

agen
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281

8.6.2

umn switch module base, manufacturer
Kostal
Note

-1- of the steering lock housing must be drilled out. New shearhead bolts are required for subsequent installation Electronics
parts catalogue (ETKA) .

Angle hand drill
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
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nl
f
e
ng
rrectness of i
t to the co
nf
o
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m
spec
atio
h re
n in
wit
Caution
ility
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AG. Volkswagen AG d
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ra
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s
Ensure that all the components mounted on the base have

function!
The removal and installation of individual components of
the steering column switch module must be performed in
a specified sequence page 274 .
Remove all components attached to base in prescribed se

quence page 274 .
282
AG.
The carrier can be removed once all the components mounted to

it have been removed:
agen
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Prote
cted
by
c
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rig
ht
.
C
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ht
rig
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Co
t.
Removing:
thi
sd
o
cu
m
en

hered to page 3 .

Drill out shear-head bolts -1- of steering lock housing -3-.
Note

module base.
Insert steering lock housing -3- into steering column switch

module base -2-.
Push steering column combination switch - E595- onto steer
ing column switch module base and screw in lower securing
bolt.
Push pre-assembled unit consisting of steering lock housing,
steering column switch module base and steering column
combination switch - E595- as far as stop onto steering column
and align it with threaded holes.
Secure steering lock housing -3- to steering column using new
Tighten new shear-head bolts -1- until bolt heads shear off.
ht
rig
py
Co
t.
c
o
p
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gh
t
.
C
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yi
Coding steering column electronics con

trol unit - J527agen
lksw
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by
AG.
Prote
cted
by
8.7
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Installing:
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
module base -2- towards rear off steering column.
ility
ab
y li
an
pt
ce
es n
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s
k
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b
Bolts M8 -1-, core diameter
6.8 mm
d
ran
ir se
tee
o
h
t
or
u
ac
a
Pull steering
ss lock housing -3- and steering column switch

Body
Electrical system
Coding steering wheel electronics control unit
283

Rear parking aid system
9.1 General description - rear parking aid system, page 284

9.2 Assembly overview - rear parking aid system, page 285
9.3 Removing and installing rear parking aid control unit, page
286
9.4 Adapting rear parking aid control unit , page 287
9.5 Removing and installing rear parking aid senders,
page 287
9.6 Removing and installing parking aid system warning buz
zer, page 288
kswagen AG
AG. Volparking
General description
-nrear
daid
oes
wage
s
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system
ara
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a
ss
The description below applies to vehicles up to 05.2012 equip
ped with a parking aid system located in the rear bumper

cover.
The parking aid system for vehicles up to 05.2012 can be
easily identified by the protruding parking aid sensors in the

bumper cover.
On vehicles as of 06.2012, the sensors are flush with the sur
face of the bumper cover.
The rear parking aid system for vehicles as of 06.2012 is de
scribed in the park assist steering chapter page 289 .

Note
When faced with complaints, it is absolutely necessary to un
derstand the function and operation of the parking aid system.

c
o
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.
C
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yi
When reversing the parking aid system supports the driver by in

dicating the distance from the rear of the vehicle to the obstacle
by way of acoustic signals.
agen
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AG.
Prote
cted
by
The rear parking aid system consists of:

Rear parking aid control unit - J446-
Rear parking aid warning buzzer - H15 Rear left parking aid sender - G203 Rear centre left parking aid sender - G204 Rear centre right parking aid sender - G205 Rear right parking aid sender - G206Fault detection and fault display:
The parking aid system is equipped with self-diagnosis, which is
designed to simplify fault finding.
ing mode page 403 .
284
ht
rig
py
Co
t.
r
fo
ng
Additional information Owner's Manual
rrectne
s
s
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f
i
t to the co
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form
spec
atio
h re
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wit
i
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or
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Note
un
le
9.1

To check the parking aid system as a whole, perform final control
diagnosis.
Note
On the first software version of parking aid control unit - J446- ,
the sender designations may differ slightly on the display due

to different software versions. In this case allocation is as fol
lows:
Rear centre left parking aid sender - G204- is rear left parking
aid sender - G203-
Rear left inner parking aid sender - G334- is rear centre left
parking aid sender - G204-
Rear right inner parking aid sender - G335- is rear centre right
parking aid sender - G205-
Rear centre right parking aid sender - G205- is rear right park
ing aid sender - G206-
9.2
Assembly overview - rear parking aid system
1 - Rear parking aid warning

buzzer - H15 Removing and installing
page 288 .
Adjusting volume of rear
parking aid warning
buzzer - H15 page 287
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
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do
c
um
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agen
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Vo
by
AG.
Prote
cted
by
6 - Rear left parking aid sender

- G203 In rear bumper cover
page 287
c
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5 - Rear centre left parking aid

sender - G204 In rear bumper cover
page 287
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
4 - Rear centre right parking

aid sender - G205 In rear bumper cover
page 287
ility
ab
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an
pt
ce
3 - Rear right parking aid send

er - G206 In rear bumper cover
page 287
AG. Volkswagen AG d
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rig
py
Co
t.
2 - Rear parking aid control unit

Behind right side panel
trim, near tail light
page 286
Adaption page 287
9. Rear parking aid system
285

9.3
Removing and installing rear parking aid

control unit
Note
In vehicles with parking aid in the rear bumper cover only, the
parking aid functions are controlled by the parking aid control

unit - J446- .
Depending on the equipment level and manufacturing date of
the vehicle, the parking aid control unit - J446- can be installed
at different locations:
Fitting location of parking aid
control unit:
Behind right side panel trim,
near tail light page 286
Behind right side panel trim,
near tail light page 286
ility
ab
y li
an
pt
ce
In footwell on driver side,Gbe

n A . Volkswagen AG do
hind relay carrierlksunder
es n
wage dash
ot g
o
panel page
y V293
ua
b
d
ran
ir se
tee
In footwell
on
driver
side,
be
o
h
t
or
u
ac
hinds arelay
carrier under dash
s
panel page 293
Removing:
key.
Remove flap in right side wall trim in luggage compartment.
Remove bracket -1-.
Remove parking aid control unit -1- from bracket, as far as the
wiring allows.
Prote
cted
by
Installing:
Use a new adhesive pad for securing.
286
AG.
Remove parking aid control unit - J446- from vehicle.
agen
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Release and disconnect electrical connectors.
ht
rig
py
Co
t.
r
fo
ng
The control unit is bonded to the body.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
Vehicle equipment and manu

facturing date:
All vehicles manufactured up to
week 22/12
Vehicles with unpainted bump
er covers manufactured from
week 22/12 up to week 45/12
Vehicles with painted bumper
covers manufactured from
week 22/12 up to week 45/12
All vehicles manufactured as of
week 45/12

9.4
Adapting rear parking aid control unit
This adaptation adapts the volume of the rear parking aid warning
buzzer - H15- .
Body
General body repairs
Parking aid
Functions
Adaptation
9.5
.
n AGaid
Removing and installing rear parking
wage
olks
V
y
senders
db
ise
Volkswagen AG
r
ho
ut bumper cover:
Following 4 senders are located in the rear
sa
s
does
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gu
ara
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ra
c
un
le
Rear centre left parking aid sender - G204 Rear centre right parking aid sender - G205 Rear right parking aid sender - G206Note
Removal and installation of the rear parking aid senders are car
ried out in the same way for all senders and are described as
follows for just one sender.
Removing:
The rear parking aid senders are accessible without removing the
bumper.
agen
lksw
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by
AG.
c
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.
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ht
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Co
t.
Note
r
fo
ng
key.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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c
um
en
ole,
cial p
is n
mer
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or
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t
a
itte
v
i
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d
p
ility
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an
pt
ce
Rear left parking aid sender - G203-
9. Rear parking aid system
287
Prote
cted
by

Release locking lugs -arrows- and remove sender from bump
er cover.
Installing:
9.6
Removing and installing parking aid sys

tem warning buzzer
Note
The volume and frequency of the parking aid warning buzzer
can be adjusted by means of the parking aid control unit

page 287 .
The parking aid warning buzzer is secured to the rack of the
relay carrier above the onboard supply control unit.
Removing:
Release relay carrier and fold downwards page 370 .
Pull out pins of both spreader rivets -1- and remove warning
buzzer.
Release and disconnect connector -2- and remove warning
buzzer.
ility
ab
y li
an
pt
ce
agen
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Vo
by
AG.
Prote
cted
by
c
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p
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C
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do
c
um
en
288
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
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g
n
Installation is carried
AG. Volkswagen AG d
agen
oes
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not
l
o
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gu
y
b
ara
d
out in reverse
order of removal.
nte
ise
r
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h
t
u
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Installing:

10
Park assist steering
wagen 289
AG do
n AG. Volkspage
10.1 General description - park assist
steering,
e
wage
ks
Vol
by
10.2 Assembly overview - park
ed assist steering, page 291
is
or
10.5 Adapting parking aid control unit J446 , page 294
rrectness of i
t to the co
nform
spec
at
i
h re
o
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wit
in t
his
10.6 Removing and installing front parking aid senders, page

295
10.7 Removing and installing rear parking aid senders,
page 297
10.8 Removing and installing front park assist steering send
er, page 300
10.9 Removing and installing rear park assist steering sender,
page 303
10.10 Renewing parking aid sender or park assist steering
sender , page 305
10.11 Renewing retainers for parking aid senders and park
assist steering senders , page 306
10.12 Removing and installing park assist steering button
E581 , page 310
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10.14 Removing and installing front parking aid warning buzzer

, page 311
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10.13 Removing and installing parking aid button E266 , page

311
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10.4 Coding parking aid control unit J446 , page 294
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th
parking aid control unit J446
au
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page 293
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10.15 Removing and installing rear parking aid warning buzzer

, page 312
10.16 Adapting parking aid warning buzzer, page 312
10.1
General description - park assist steer

ing
Note
When faced with complaints, it is absolutely necessary to un
derstand the function and operation of the park assist and

parking aid system.
Additional information Operating manual

Vehicles with park assist steering are always equipped with the
front and rear parking aid systems. The front parking aid system
is only installed in conjunction with the park assist steering sys
tem.
The park assist steering supports the driver when reversing into
a parallel parking space on the driver or passenger side. When
the park assist steering is activated and the vehicle drives by at
a speed of less than 35 km/h, the side of the road is measured by
ultrasonic sensors searching for a suitable parking space. Once
a parking space has been reliably detected, the park assist steer
ing requests the driver to continue passing by the parking space
until the vehicle is in a position from which rapid parking is pos
sible. When the reverse gear is engaged, the park assist steering
system undertakes lateral guidance of the vehicle by actuating
the EPS (electronic power steering = electromechanical steering).
10. Park assist steering
289

The system steers the vehicle into the parking space in one
movement according to a calculate nominal path. The driver
maintains operation of the pedal cluster (accelerator, clutch,
brake) and longitudinal vehicle guidance, and therefore deter
mines the parking speed. During the parking process, the park
assist steering sensors are used together with the parking aid
senders to monitor proximity.
The Caddy features a second-generation park steering assist
system. This enables parking in an even shorter parking space.
Apart from the new function of transverse parking, longitudinal
parking also has new functions, such as; the partial or complete
parking on a kerb, parking between other obstacles (trees, bush
es or motorcycles) as well as parking on bends. Furthermore it
enables driving out of parallel parking spaces.
The following conditions lead to abortion of the parking process
with the park assist steering:
The park assist steering is switched off via the park assist
steering button - E581- .
Ignition is switched off
Parking speed too high (>7 km/h)
Steering intervention by driver during parking process
Disengaging reverse gear
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Vehicle standstill time limit exceeded (approx. 30 s)

ESP switched off or ESP intervention
un
le
Front parking aid system is switched on.
Sensors detect a status which endangers secure determina

tion of the vehicle position.
System malfunction
WARNING
Responsibility during parking is borne by the driver.

The park assist steering cannot replace the driver's atten
tiveness.
The sensors have blind spots, in which persons and ob
jects can not be registered.
Front right parking aid sender - G252 Front centre right parking aid sender - G253 Front centre left parking aid sender - G254 Front left parking aid sender - G255-
290
Prote
cted
by
Rear right parking aid sender - G206-
AG.
Rear centre right parking aid sender - G205-
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Rear centre left parking aid sender - G204-
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Rear left parking aid sender - G203-
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The park assist steering consists of:
r
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Pay particular attention to small children and animals, as

these are not always detected by the sensors.
rrectne
s
s
o
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t to the co
n
form
spec
atio
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Trailer attached to vehicle coupling
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TCS intervention

Front left sender for park assist steering on left side of vehicle
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Front right sender for park assist steering on right side
isof
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hicle - G569au
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Rear left park assist steering sender - G716-
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Rear right park assist steering sender - G717-
rrectness of i
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Rear parking aid warning buzzer - H15-
Front parking aid warning buzzer - H22 Parking aid button - E266 Park assist steering button - E581 Button illumination bulb - L76-
Warning light for park assist steering - K241 Parking aid control unit - J446-
Park assist steering control unit - J791Fault detection and fault display:
Assembly overview - park assist steering
AG.
10.2
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To check the park assist steering as a whole, perform final control

diagnosis.
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ing mode page 403 .
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The park assist steering features self-diagnosis to facilitate fault

finding.
291

1 - Park assist steering button
- E581 Installed in centre con
sole storage compart
ment in front of gearbox
selector lever.
page 310 .
2 - Parking aid button - E266 Installed in centre con
sole storage compart
ment in front of gearbox
selector lever.
page 311 .
3 - Park assist steering sender
on right in rear bumper cover G717 Rear left park assist
steering sender - G716 Removing and installing
page 303 .
Renewing sender
page 305 .
Renewing sender re
tainer page 306
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4 - Rear parking aid warning
ksw
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buzzer - H15d
e
ris
Installed behind side utho
a
panel trim of left B-pillar.
ss
page 312 .
Can be checked via final
control diagnosis
Adaption page 312
5 - Rear parking aid senders

Rear left parking aid sender - G203 Rear centre left parking aid sender - G204 Rear centre right parking aid sender - G205 Rear right parking aid sender - G206 Removing and installing page 297 .
Renewing sender page 305 .
Renewing sender retainer page 306
do
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6 - Park assist steering senders on left in rear bumper cover - G716 Removing and installing page 303 .
Prote
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7 - Parking aid control unit - J446 With integrated park assist steering control unit - J791 Located in driver side footwell, on left side of dash panel behind relay carrier
Coding page 294 .
Adaption page 294
Securing bolt specified torque: 5 Nm
AG.
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292

8 - Front parking aid warning buzzer - H22 In driver side footwell, on left side of dash panel behind relay carrier
Can be checked via final control diagnosis
Adaption page 312
9 - Front left sender for park assist steering on left side of vehicle - G568 Removing and installing page 300 .
10 - Front parking aid senders
Front left parking aid sender - G255 Front centre left parking aid sender - G254 Front centre right parking aid sender - G253 Front right parking aid sender - G252 Removing and installing page 295 .
Renewing sender retainer page
AG. Volkswagen AG d
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Note
The parking aid control unit - J446- with integrated park assist
steering control unit - J791- can be found in the driver's foot

well behind the relay carrier of the dash panel.
The parking aid control unit - J446- also simultaneously con
trols the park assist steering functions on vehicles with park

assist steering.
Removing:
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Remove relay carrier, above onboard supply control unit, on

left of dash panel page 370 .
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Removing and installing parking aid

control unit - J446-
rrectness of i
t to the co
nform
spec
at
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10.3
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t g-u G569y V sender in front bumper cover

11 - Front right park assist steering
ara
db
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ir se
page 300 .
eo
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Renewing sender
ss page 305 .
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Remove data bus diagnostic interface and lay it aside with

wiring harness connected page 388 .
AG.
Prote
cted
by
Pull out onboard supply control unit and move it aside with
wiring harness connected page 382 ,
293

ility
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an
pt
ce
rrectness of i
t to the co
nform
spec
a
t
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wit
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s
es, in part or in w
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hole
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com
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Remove bolt from below -arrow- and remove
control
unit
from
ra
a
c
s
s
its installation position as far as the connected
wiring allows.
Release and disconnect the three electrical connectors

-arrows-. Remove control unit -1- from vehicle.
Installing:
Install in the reverse order of removal observing the following:

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Prote
cted
by

Body
Parking aid ll -J446 Parking aid ll functions
Coding
10.5
Adapting parking aid control unit - J446-
With this function, the following adaptions can be set in the park
ing aid control unit - J446- :
Volume reduction in conjunction with parking aid
Activation sound when parking aid is switched on
Optical display for assisted parking
Body
294
AG.
Coding parking aid control unit - J446-
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10.4
ht
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Tighten bolt to torque specified in assembly overview

page 291 .
do
c
um
en
When installing, insert corner of control unit into opening in

relay carrier again.

Adaption
10.6
Removing and installing front parking

aid senders
Note
The front parking aid senders - G255, G254, G253, G252- are
installed in the front bumper cover.
Removal of the four front parking aid senders is carried out in
the same way and is only described as follows for one sender.
G. Volkswagen AG d
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When installing a new park assist steering sender or parking
lksw
es, in part or in w
l purpos
hole
ercia
, is n
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o
aid sender, the sender head must be first painted in the colour
yV
db
e
of the bumper cover page 305 .
ris
ho
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a
ss
Removing:
key.
Caution
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Rep. gr. 63 ; Front bumper, up to 2011 or General body
repairs, exterior; Rep. gr. 63 ; Front bumper, as of 2011 .
The order for removing the senders must be adhered to

under all circumstances.
The sender may otherwise be damaged. Fractures may
occur if too much pressure is applied to the sender, and
this may cause the sender to fail.
First remove the sender from the retainer and then release
and disconnect the sender's connector.
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Note
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Pull out sender -2- with wiring connected backwards from

sender holder -1-.
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Push fasteners -arrows- on sender bracket -1- outwards.
When removing the sender, ensure the isolation ring (black
silicone ring) remains on the sender head and does not remain
stuck in the bracket or become lost.
Expanding the isolation ring must be avoided under all cir
cumstances.
295

Release and disconnect connector -2- and remove sender
-1-.
Installing:
following:
Caution
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Expanding the isolation ring must be avoided under all

circumstances.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Function problems could occur if an incorrect or damaged

isolation ring is used.
Replace any damaged isolation rings and make sure that
the right isolation ring is fitted in each case.
Note
As the front parking aid sender and the park assist steering send
ers have sender heads of different lengths, isolation rings of
different heights are also installed.
Assign sender to correct installation position in bumper cover.

Note
Senders are available in different forms and must be assigned
to respective fitting location in bumper cover.
When installing senders, note position of electrical connec
tions of senders.
296
AG.
Renew isolation ring -1- of sender if necessary.
agen
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5.7 mm
9.05 mm
ht
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Front parking aid senders

Park assist steering senders
Isolation ring height dimen

sion -B-
do
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um
en
Type of sender
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Check whether the correct isolation ring is installed on the re

spective sender head.

Assignment of parking aid sender on inside of rear bumper cover:
A - Left outer
B - left centre
C - right centre
D - Right outer
Note
When installing the sender, ensure that the isolation ring is
correctly mounted on the sender head and does not ride or roll
up on insertion into the sender bracket.
Both locking lugs of sender retainer must audibly engage
when installing the sender.
After installing the sender, check that the sender is correctly

seated in the bracket. Visible on the outer side of the bumper,
dimension -a- of the ring gap between the sender head and
bumper cover must be even all around.
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senders
Note
rrectness of i
t to the co
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spec
atio
h re
n in
wit
The rear parking aid senders - G203, G204, G205, G206- are
ility
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ce
installed in the rear bumper cover.
The removal of the four rear parking aid senders is carried out
in the same way and is only described for one sender in the
following.
Removing:
key.
Remove rear bumper cover General body repairs, exterior;
Rep. gr. 63 ; Rear bumper .
When removing rear bumper completely:
agen
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If only one parking aid sender or park assist steering sender is to

be renewed, wiring harness can remain installed on bumper.
However, the removed bumper must be held by a second person
while replacing respective item.
ht
rig
py
Co
t.
Unclip wiring harness retainers in bumper, use a second per

son to hold removed bumper when unclipping retainers.
thi
sd
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en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
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or
e
t
a
itte
iv
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du
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f
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10.7
297
AG.

Pull covers upwards off parking aid senders in
Press catches on parking aid senders in -direction of arrowand pull sender, on rubber cap, out of bumper.
es n
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o
When removing the sender, ensure the isolation
ring
(black
h
t
or
u
ac
a
silicone ring) remains on the sender head and
does
not
remain
ss
Note
pe
rm
itte
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stuck in the bracket or become lost.
AG.
Prote
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298
do
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rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
cumstances.
ht
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Co
t.

-1-.
Caution
The order for removing the senders must be adhered to

under all circumstances.
The sender may otherwise be damaged. Fractures may
occur if too much pressure is applied to the sender, and
this may cause the sender to fail.
First remove the sender from the retainer and then release
Installing:
following:
Caution

circumstances.
Function problems could occur if an incorrect or damaged
isolation ring is used.
Replace any damaged isolation rings and make sure that
the right isolation ring is fitted in each case.
es n
wage
s
k
l
ot g
Vo
y
ua
b
Note
d
ran
ir se
tee
o
h
t
or
u
ac
a
As the rear parking aid senders and
the
park
assist
steering
send
ss
Check whether the correct isolation ring is installed on the re

spective sender head.
Type of sender

sion -B-
Rear parking aid senders

5.7 mm
9.05 mm

Assign sender to correct installation position in bumper cover.
Note
Senders are available in different forms and must be assigned

When installing senders, note position of electrical connec
agen
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tions of senders.
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t.
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fo
ng
to respective fitting location in bumper cover.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
ility
ab
y li
an
pt
ce
ers have sender heads of different lengths, the isolation rings

installed are of different heights accordingly.
299

Assignment of senders on inside of rear bumper cover:
A - Bracket for rear right park assist steering sender - G717B - Bracket for rear left park assist steering sender - G716Note
AG. Volkswagen AG d
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no
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ed
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ility
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ho
ut
a
ss
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Removing and installing front park as

sist steering sender
The front left sender for park assist steering on left side of ve
Prote
cted
by
ermost, lateral positions of the bumper cover, and are used to

measure proximity during the parking process, together with
the parking aid senders.
Removing:
key.
Rep. gr. 63 ; Front bumper, up to 2011 or General body
repairs, exterior; Rep. gr. 63 ; Front bumper, as of 2011 .
300
AG.
The two park assist steering senders are mounted at the out
agen
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.
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hicle - G568- and front right sender for park assist steering on
right side of vehicle - G569- are installed in the front bumper
cover.
do
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um
en
Note
ht
rig
py
Co
t.
10.8
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his


Caution
The order for removing the senders must be adhered to under

all circumstances.
The sender may otherwise be damaged. Fractures may occur
if too much pressure is applied to the sender, and this may
cause the sender to fail.
First remove the senders from the retainers and then release
sender holder.
Note
When removing the sender, make sure that the isolation ring
(black silicone ring) on the sender head does not remain in the
bracket or become lost.
Stretching the isolation ring must be avoided under all circum
stances.
Release and disconnect

-1-.
following:
Caution
Function problems could occur if an incorrect or damaged iso

lation ring is used.
Stretching the isolation ring must be avoided under all circum
stances.
Replace any damaged isolation rings and make sure that the
right isolation ring is fitted in each case.
r
fo
ng
As the front parking aid sender and the park assist steering send
ers have sender heads of different lengths, isolation rings of
different heights are also installed.
ht
rig
py
Co
t.
Note
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
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p
un
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ility
ab
y li
an
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Installing:
AG. Volkswagen AG d
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ara
d
e
nte
connector
is -2- and remove sender
r
o
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ut
ra
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s
s
301
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AG.
Prote
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Check whether the correct isolation ring is installed on the
sender head.
Type of sender

sion -B-
Front parking aid senders

pe
rm
itte
d
es, in part or in w
l purpos
hole
ercia
, is n
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ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
When installing senders, note position of electrical connections

of senders.
ility
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Note
un
le
If necessary, renew
. Volkswagen AG
5.7
n AGmm
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9.05
mm
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h
t
isolation
ring
-1of
sender.
u
ra
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ss
Assignment of senders on inside of front bumper cover:

A - Bracket for front left sender for Park Assist on left side of ve
hicle - G568B - Bracket for front right sender for Park Assist on right side of
vehicle - G569Note

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by
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302
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10.9
Removing and installing rear park assist

steering sender
Note
The rear left park assist steering sender - G716- and rear right
park assist steering sender - G717 - are installed in the rear

bumper cover.
The two park assist steering senders are mounted at the out
ermost, lateral positions of the bumper cover, and are used to

measure proximity during the parking process, together with
the parking aid senders.
Removing:
key.
Remove rear bumper cover General body repairs, exterior;
Rep. gr. 63 ; Rear bumper .
When removing rear bumper completely:
Unclip wiring harness retainers in bumper, use a second per
son to hold removed bumper when unclipping retainers.
AG. Volkswagen AG d
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Caution
un
le
ksw
If only one parking aid sender or park assist steering
is to
olsender
yV
bon
be renewed, wiring harness can remain installed
bumper.
d
e
s
ri a second person
However, the removed bumper must be heldthoby
u
a
while replacing respective item.
s
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
The order for removing the senders must be adhered to under

all circumstances.
The sender may otherwise be damaged. Fractures may occur
if too much pressure is applied to the sender, and this may
cause the sender to fail.
First remove the senders from the retainers and then release
(black silicone ring) on the sender head does not remain in the
bracket or become lost.
AG.
Prote
cted
by
cumstances.
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When removing the sender, make sure that the isolation ring
do
c
um
en
Note
r
te o
iva
r
rp
fo
g
n

sender holder.
303

-1-.
Installing:
following:
Caution
Function problems could occur if an incorrect or damaged iso

lation ring is used.
AG. Volkswagen AG d
oes
not
gu
ara
nte
eo
sure that the
ra
c
agen
Stretching the isolation ring must be avoided
kswunder all circum
Vol
y
stances.
db
e
ris
As the parking aid senders and the park assist steering senders
have sender heads of different lengths, isolation rings of different
heights are also installed.
Check whether the correct isolation ring is installed on the
sender head.
Type of sender

sion -B-
Rear parking aid senders

5.7 mm
9.05 mm
AG.
Assignment of senders on inside of rear bumper cover:

A - Bracket for rear right park assist steering sender - G717B - Bracket for rear left park assist steering sender - G716Note
304
agen
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When installing senders, note position of electrical connections

of senders.
ht
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Co
t.
Note
r
fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
Note
ole,
cial p
is n
mer
m
ot p
o
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erm
or
e
t
a
itte
v
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d
p
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ility
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pt
ce
ho
Replace any damaged isolationutrings
and make
a case.
s
right isolation ring is fitted in each
s

10.10
Renewing parking aid sender or park

assist steering sender
Note
If a new park assist steering sender or parking aid sender is
installed, the sender head must be first painted in the colour

of the bumper cover.
The following prerequisites must be adhered to when painting
the senders to ensure the function of the system is not affec

ted.
Painting senders:
Take insulation ring
Paint sender in area to be painted -2- in colour of bumper cov

er.
Note
Dimension -B- for the painted area must not exceed 3 mm (+

maximum 2 mm).
Fit isolation ring (black silicone ring) on sender head again
once paint has dried.
Caution

circumstances.
Renew damaged isolation rings.
ht
rig
py
Co
t.
r
fo
ng
Function problems may occur if a damaged isolation ring

is used.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
Remove grease from sender head -1- in area to be painted

-2- with isopropanol.
ility
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y li
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pt
ce
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is
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h
(black
ut silicone ring) off sender head
ra
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s
305
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10.11
Renewing retainers for parking aid

senders and park assist steering send
ers
G. Volkswage
nA
wage
olkscentre parking
10.11.1 Assembly overview - retainers for front
yV
b
d
aid senders , page 306
ise
r
ho
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
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erm
or
e
t
a
itte
iv
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f
e
ng
ility
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an
pt
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ut for front parking aid

10.11.2 Assembly overview - retainers
sa
s
senders and front park assist steering senders , page 307
n AG d
oes
not
gu
ara
nte
eo
ra
c
10.11.3 Assembly overview - retainers for rear parking aid

senders and rear park assist steering senders , page 309
10.11.1
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
10.11.4 Painting holders, page 310
Assembly overview - retainers for front

centre parking aid senders
Note
Following illustration shows the assembly overview of the retainer

with a recess for the connector on the right-hand side. The as
sembly overview for the retainer with the recess for the connector
on the left-hand side is similar (mirror image of right-hand side).
5 - Decoupling ring
6 - Sender
306
AG.
4 - Sender holder
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3 - Marking of installation posi

tion
VRM - Front centre right
parking aid sender G253 VLM - Front centre left
parking aid sender G254-
ht
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Co
t.
2 - Adhesive pad
Adhesive pad is already
stuck on holder during
production
Foam adhesive tape TL
52018-E, s=1
Qty. 2, 30 x 20, A =
12 cm2
thi
sd
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en
1 - Outline of sender holder

Outline > 1 mm to holder
Line < 2 to horizontal

Assembly:
ility
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or
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a
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p
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ara cover and
Place holder
d in installation position of inner bumper
e
nte
s
i
r
outline installation
area.
o
eo
h
ut
ra
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c
s
s
Note
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
When marking the outline, ensure that it is 1 mm greater than the

holder. The deviation of the line to the horizontal should be less
than 2.
Clean area within outline and, if necessary, remove any re
sidual glue from old holder. Degrease area with isopropanol.
Remove backing from adhesive tape and bond holder in in
stallation position of inner bumper cover.
10.11.2
Assembly overview - retainers for front

parking aid senders and front park assist
steering senders
Note
ht
rig
py
Co
t.
r
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ng

307
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1 - Outline of sender holder
Outline > 1 mm to holder
Line < 2 to horizontal
2 - Adhesive pad
production
52018-E, s=1
Qty. 2, 30 x 20, A =
12 cm2
tion
VR - Front right parking
aid sender - G252 VL - Front left parking
aid sender - G255 VLS - Front left sender
for park assist steering
on left side of vehicle G568 VRS - Front right sender
for park assist steering
on right side of vehicle G5695 - Decoupling ring
6 - Sender
ility
ab
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t
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ra
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s
s
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
4 - Sender holder
Place holder in installation position of inner bumper cover and

outline installation area.
Note

than 2.
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308
thi
sd
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cu
m
en


Assembly overview - retainers for rear

parking aid senders and rear park assist
steering senders
ility
ab
y li
an
pt
ce
Note

ht
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tion
HL - Rear left parking
aid sender - G203 HLM - Rear centre left
parking aid sender G204 HMR - Rear centre right
parking aid sender G205 HR - Rear right parking
aid sender - G206 HLS - Rear left park as
sist steering sender G716 HRS - Rear right park
assist steering sender G717-
thi
sd
o
cu
m
en
1 - Adhesive pad
production
52018-E, s=1
Qty. 2, 30 x 20, A =
12 cm2
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
10.11.3
AG. Volkswagen AG d
agen
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3 - Sender holder
4 - Decoupling ring
5 - Sender
Place holder in installation position of inner bumper cover and

outline installation area.
Note

than 2.
309

10.11.4
Painting holders
If a new retainer for a park assist steering sender is installed, the

retainer must first be painted in the required area in the colour of
the bumper cover.
Paint area for:
holder of front left sender for park assist steering on left side
of vehicle - G568 holder of front right sender for park assist steering on right side
of vehicle - G569 holder of rear left park assist steering sender - G716 holder of rear right park assist steering sender - G717Paint area on holder:
1 - Paint area
2 - Adhesive tape s=1
3 - Sender
4 - Bumper cover
5 - Decoupling ring
Paint:
Degrease holder in area to be painted -1- with isopropanol.
Paint holder in area to be painted -1- in colour of bumper cover.
AG. Volkswagen AG d
agen
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is
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h
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ra
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s
10.12
Removing and installing park assist

steering button - E581-
The park assist steering button is located in the centre console

storage compartment in front of the gearbox selector lever. It con
tains the warning light for park assist steering - K241- and cannot
be disassembled any further.
agen
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cted
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AG.
310
do
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Removal and installation of the park assist steering button - E581are carried out in the same way for all buttons in the centre
console storage compartment and are described in chapter
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
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y li
an
pt
ce
un
le
Once the paint has dried, bond holder in bumper cover.

10.13
Removing and installing parking aid but

ton - E266-
The parking aid button is located in the centre console storage

compartment in front of the gearbox selector lever. It cannot be
disassembled.
Removal and installation of the parking aid button - E266- are
carried out in the same way for all buttons in the centre console
storage compartment and is described in chapter
10.14
Removing and installing front parking

aid warning buzzer
Note
The acoustic warning messages of the park assist steering
system are given via the parking aid warning buzzer ( rear
parking aid warning buzzer - H15- and front parking aid warn
ing buzzer - H22- ).
AG. Volkswagen A
gen
swa
G do
es n
ot g
ua
ran
tee
or
ac
lk located under
The front parking aid warning buzzer - H22Vois
by
ed attached above the

the dash panel in the driver footwell. Itrisis
o
h
onboard supply control unit on the rack
of the relay carrier.
ut
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
Removing:
a
ss
key.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Remove relay carrier, above onboard supply control unit, on

left of dash panel page 370 .
Remove data bus diagnostic interface and lay it aside with
wiring harness connected page 388 .
Pull out onboard supply control unit and move it aside with
wiring harness connected page 382 ,
Pull out pins of both expansion rivets -arrows- and remove
front parking aid warning buzzer - H22- -1- under considera
tion of connected line lengths.
do
c
um
en
ht
rig
py
Co
t.
311
agen
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by
AG.
Prote
cted
by
c
o
p
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op
yi

Release and disconnect connector -arrow- and remove front
parking aid warning buzzer - H22- -1- from vehicle.
Installing:
10.15

warning buzzer
Note
The rear parking aid warning buzzer - H15- -arrow- is located be

hind upper trim of left B-pillar.
Removing:
Remove upper trim of left B-pillar General body repairs,

interior; Rep. gr. 70 ; Removing and installing upper trim of Bpillar (Kombi) .
c
o
p
yri
gh
t
.
C
op
yi
Release and disconnect connector -arrow- and remove rear

parking aid warning buzzer - H15- -1- from vehicle.
agen
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AG.
Prote
cted
by
Installing:
ht
rig
py
Co
t.
r
fo
ng
Pull out pins of both expansion rivets and remove rear parking
aid warning buzzer - H15- , as far as the connected cables will
allow.
10.16
Adapting parking aid warning buzzer
With this function, the following functions of the parking aid warn
ing buzzer can be adapted:
Frequency of parking aid speaker
Volume of parking aid loudspeaker
Body
312
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
ility
ab
y li
an
pt
ce
un
le

Adaption
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
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y li
an
pt
ce
AG. Volkswagen AG d
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313
AG.
Prote
cted
by
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.
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11
Towing bracket
11.1 General description - towing bracket, page 314

11.2 Removing and installing trailer socket U10 , page 314
11.3 Pin assignment of trailer socket U10 , page 317
11.4 Removing and installing trailer detector control unit ,
page 318
11.1
General description - towing bracket
For vehicles manufactured from calendar week 22/2013 onwards,

a preparation for towing bracket can be ordered as an option. This
applies for all vehicles for which a towing bracket can be or
dered.
During production, the same modules are fed to the vehicle as is
the case for the version with towing bracket. These modules
include e.g.:
Cooler module
Battery
Alternator
The following components or preparations are installed:
Wiring harness up to coupling point on right D-pillar
Trailer detector control unit - J345- including bracket and
all
. Volkswagen AG
gen AG
add-on parts
does
a
w
s
k
Vol
by
The following control units and the module
edfamily for convenience
ris
o
electronics must be coded for towing mode:
th
au
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
ss
Onboard supply control unit - J519-
not
gu
ara
nte
eo
ra
c
Data bus diagnostic interface - J533 Control unit for ABS with EDL - J104-
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Parking aid control unit - J446-
Reversing camera system via reversing camera system con

trol unit - J772 Anti-theft alarm system via convenience system central con
trol unit - J393-
11.2
Removing and installing trailer socket U10-
11.2.1 Removing and installing trailer socket U10 ,

page 314
If the trailer socket is to be repaired due to, e.g. corrosion,
Because part numbers may vary, check if the installed trailer
socket is original equipment or a retrofitted accessory before

ordering the replacement part.
314
AG.
check whether it is sufficient to renew individual contacts or

seals, or if the entire wiring harness with trailer socket must be
renewed.
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Note
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Removing and installing trailer socket U10ht

rig
py
Co
t.
11.2.1

Removing
ignition key.
Remove trailer socket - U10- from retaining plate.
Pull rubber cover off trailer socket.
ility
ab
y li
an
pt
ce
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
un
le
AG. Volkswagen AG d
agen
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ara
Depending on equipment level, disconnect connector
-2- for
d
e
nte
s
i
r
rear fog light cut-out contact switch - F216.
o
eo
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ut
ra
a
c
s
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Release fasteners -arrows-, and remove multi-pin connector

frame -2-.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Push multi-pin connector -2- in direction of -arrowout of sock

et housing -1-.
11. Towing bracket
315

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
following:
Note
The retaining cage -1- can only be pushed onto the multi-pin
connector -3- and engaged in one specific position.
The guide pins -4- on retaining cage -1- only fit into the multi-
pin connector -3- in one specific position.
To insert the guide pins into the multi-pin connector all con
tacts -2- must be properly inserted in the retaining cage at the

correct positions.
pe
rm
itte
d
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Note
Be especially careful that seals -1- and -3- are not damaged.
Slide multi-pin connector in correct installation position from
behind into socket housing.
Fit rubber cover onto socket housing and fit trailer socket to
retaining plate.
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Push multi-pin connector -4- into retaining cage -2- until it en

gages audibly.
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Insert contacts -2- in retaining
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cage into multi-pin connector
-3- until it engages audibly. rante
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11.3
Pin assignment of trailer socket - U10-
11.3.1 Pin assignment of trailer socket U10 , page 317
11.3.1
Pin assignment of trailer socket - U10-
Pin assignment of trailer socket - U10- with rear fog light cut-out
contact switch - F2161-
Terminal BLL (left turn signal)
2-
Terminal NSL (rear fog lamp)
3-
Terminal 31 (earth)
4-
Terminal BRR (right turn signal)
5-
Terminal 58 R (right tail light)
6-
Terminal 54 (brake light)
7-
Terminal 58 L (left tail light)
8-
Terminal RFL (back-up lamp)
9-
Terminal 30 (Battery +), permanent positive, low permis

sible current range, approx. 7.5 to 10 A
10 - Reserved for terminal 30
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11. Towing bracket
317
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11.4
Removing and installing trailer detector

control unit
Note
The trailer detector control unit - J345- -arrow- is located behind

the rear right side panel trim.
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The trailer detector control unit - J345- detects from a power draw
of minimum 5 W3) the trailer operation and transmits this infor
mation to various control units via the CAN data bus.
The trailer detector control unit - J345- is supplied with information
(light control) from the onboard supply control unit - J519- and
convenience system central control unit - J393- via the CAN data
bus.
3) Left turn signal light or brake light as a minimum must be switched on, in order
to detect trailer operation.
The trailer detector control unit - J345- manufactured by Hella is

not self-diagnosis capable.
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The trailer detector control unit - J345- detects trailer operation

from a power draw of minimum 5 W on brake light or left turn signal
switch.
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Currently, only control units not capable of self-diagnosis (man

ufacturer Hella) are installed on Caddy vehicles.

TORX bit range - V.A.G 1766-
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Removing:
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Switch off thignition
and all electrical loads, and pull outnignition
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Remove right-hand luggage compartment side trim panel

General body repairs, interior; Rep. gr. 70 ; Load, luggage
compartment trim .
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Pull guide clip -2- out of bracket and place cable as far to one
side as the cable length allows.
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Remove the bracket together with trailer detector control unit

- J345- from the vehicle.
rrectness of i
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Release connector -1- and disconnect it from trailer detector

control unit - J345- .
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Remove trailer detector control unit - J345- from bracket.
Installing:
Tighten bolt for securing control unit to bracket to 9 Nm.
Tighten bolt securing bracket to body to 9 Nm.
11. Towing bracket
319

96
Lights, bulbs, switches - interior
Lights and controls in the dash panel
1.1 Removing and installing light switch , page 320

1.2 Removing and installing headlight range control regulator
and switch and instrument illumination regulator , page 321
1.3 Removing and installing front passenger side airbag de
activated warning lamp , page 322
1.4 Removing and installing hazard warning light switch E229
, page 323
1.5 Removing and installing key operated switch to deactivate
front passenger front airbag , page 324
1.1
Removing and installing light switch
The following components are integrated into the light switch E1- :
Note
Fog light switch - E7 Rear fog light switch - E18 Bulb for illumination of light switch - L9Removing:
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Rep. gr.96 - Lights, bulbs, switches - interior
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Hold rotary grip in this position and pull light switch out of dash
panel using rotary grip -3-.
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Press rotary position indicator of light switch firmly inwards

-1- and turn slightly to right -2-.
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Switch off ignition and all electrical
loads,
and
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Turn rotary knob parts of light switch to 0.

Installing:
Connect connector to light switch.
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Hold rotary grip in this position and insert light switch in dash
panel -3-.
Turn rotary grip to 0 position, release and engage switch.
Note
r
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control regulator and switch and instru
ment illumination regulator
The headlight range control regulator - E102- and the switch
(switches, covers, trim and so on), mask off areas in which

tools ( removal wedge - VAS 3409- , screwdriver) are used to
lever out those components using commercially available
masking tape.
AG.
When removing and installing components that are in view
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Holding light switch, press rotary position indicator of light

switch firmly inwards -1- and turn slightly to right -2-.

Removal wedge - VAS 3409-
Removing:
key.
1. Lights and controls in the dash panel
321

Remove storage compartment on driver side General body
repairs, interior; Rep. gr. 68 ; Compartments, covers; Remov
ing and installing storage compartment on driver side .
Release locking lugs -arrows- and take out adjuster and reg
ulator.
Installing:
1.3
Removing and installing front passenger

side airbag deactivated warning lamp
Removing:
key.
Pull ashtray out of centre console.
Pull trim out of centre console a little.
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Release and disconnect electrical connectors -arrows-.
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Release locking lugs
and remove warning
ks-arrowsnot lamp from
Vol
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trim.
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Installing:
1.4
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Removing and installing hazard warning

light switch - E229-
Removing:
key.
r
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Remove trim from centre of dash panel General body re

pairs, interior; Rep. gr. 68 ; Compartments, covers and trim;
Removing and installing trim in centre of dash panel .
Operating and display unit for heating, or removing the air

conditioning Heating, air conditioning; Rep. gr. 80 ; Oper
ating and display unit or heating, air conditioning; Rep. gr.
87 ; operating and display unit .
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AG.
Release locking lugs -arrows- and take out hazard warning

light switch - E229- .
Installing:
1. Lights and controls in the dash panel
323

olkswagen AG
Removing and installingagekey
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front airbag tho
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of the airbag!
Observe safety precautions when working on airbag.
Removing:
key.
Remove passenger side lower compartment General body
repairs, interior; Rep. gr. 68 ; Compartments, covers and trim;
Removing and installing passenger side lower compartment .
AG.
Installing:
324
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Release locking lugs -arrows- and remove key operated

switch.
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WARNING
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1.5

Lights and controls in front doors
2.1 Removing and installing front left window regulator switch,

page 325
2.2 Removing and installing front right window regulator
switch, page 326
2.3 Removing and installing switch for exterior mirror adjust
ment and button for central locking, driver side, page 327
2.4 Removing and installing door contact
rrectness of i
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Removing and installing front left win

dow regulator switch
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l purpos
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2.1
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switch, pageed327
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Depending on vehicle equipment, the front left window regu
lator switch may have 2 or 4 buttons.
The removal and installation of the front left window regulator
switch is carried out in the same way for both versions.
Removing:
key.
Using removal wedge - 3409- , carefully lever handle trim at
catches -arrows- out of door trim.
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Release and disconnect connector -arrow-, and remove han

dle trim -1-.
2. Lights and controls in front doors
325

Release locking lugs -arrows-, and remove switch module
-1- from handle trim -2-.
Installing:
2.2
Removing and installing front right win

dow regulator switch
Removing:
key.
Remove door trim General body repairs, interior; Rep. gr.
70 ; Door trims; Front door trim; Removing and installing .
Release locking lug -arrow- and remove switch together with
mounting frame from door trim.
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Release locking lugs -arrows- and remove switch from mount

ing frame.
Installing:
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326
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Removing:
key.
Remove door trim General body repairs, interior; Rep. gr.
70 ; Door trims; Front door trim; Removing and installing .
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Undo bolts -arrows- and remove cover.
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atio
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Removing and installing switch for exte

rior mirror adjustment and button for
central locking, driver side
ole,
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2.3
AG. Volkswagen AG d
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Caddy
2004
,
Caddy
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h
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Electrical
system
Edition
c10.2014
s
s
Remove trim of door opener together with switches from the

door trim.
Unclip mounting frame of switches from trim.
Release locking lugs -arrows- and remove central locking

switch from mounting frame.
Note
The adjustment switch for mirror with fold-in feature - E43- is

joined permanently to the mounting frame. In the event of repair,
the complete component must be renewed.
Installing:
2.4
Removing and installing door contact

switch
The door contact switch is integrated into door lock and cannot
be replaced separately.
The complete door lock must always be renewed if the door con
tact switch is defective.
Replace the corresponding door lock General body repairs,
exterior; Rep. gr. 57 or General body repairs, exterior; Rep.
gr. 58 .
2. Lights and controls in front doors
327

Lights and controls in sliding doors
3.1 Removing and installing contact strip in left sliding door ,

page 328
3.2 Removing and installing contact strip in right sliding door
, page 330
. Volkswage
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3.3 Removing and installing rear door contact switches
for
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sliding door or side door , page 330
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Removing and installing contact strip in

left sliding door
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3.1.1 Removing and installing contact strip in left sliding door ,

B-pillar, page 328
3.1.2 Removing and installing contact strip in left sliding door ,
sliding door, page 329
3.1.1

left sliding door , B-pillar
Note
In the Caddy, the contact strip in left sliding door - F353- is
used only in vehicles with central locking.
The contact strip in left sliding door - F353- comprises a con
Installing:
328
AG.
Remove contact strip in -direction of arrow-.
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Removing:
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tact carrier (wedge) in the sliding door and a contact strip

(bush) in the B-pillar.

3.1.2

left sliding door , sliding door
Note
In the Caddy, the contact strip in left sliding door - F353- is
The contact strip in left sliding door - F353- comprises a con
tact carrier (wedge) in the sliding door and a contact strip

Removing:
key.
rrectness of i
t to the co
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es, in part or in w
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Remove contact strip in -direction of arrow-.

Installing:
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3. Lights and controls in sliding doors
329
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3.2

right sliding door
3.2.1 Removing and installing contact strip in right sliding door ,

B-pillar, page 330
3.2.2 Removing and installing contact strip in right sliding door ,
sliding door, page 330
3.2.1

right sliding door , B-pillar
Note
In the Caddy, the contact strip in right sliding door - F352- is
The contact strip in right sliding door - F352- comprises a con
tact carrier (wedge) in the sliding door and a contract strip

Removal and installation of the contact strip in the right B-pillar

are carried out in the same way as the removal and installation
of the contact strip in the left B-pillar page 328 .
3.2.2

AG. Volkswagen AG d
right slidingswdoor
agen , sliding door
oes
In the Caddy, the contact strip in right sliding door - F352- is
The contact strip in right sliding door - F352- comprises a con
Removal and installation of the contact strip in the right sliding

door are carried out in the same way as the removal and in
stallation of the contact strip in the left sliding door
page 329 .
3.3
Removing and installing rear door con

tact switches for sliding door or side door
3.3.1 Removing and installing rear left door contact switch for
3.3.2 Removing and installing rear right door contact switch for
Removing and installing rear left door

contact switch for sliding door or side
door
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Note
The rear left door contact switch for sliding door or side door F176- is located in the bush (B-pillar), which is activated and
deactivated by a wedge in the sliding door.
330
do
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3.3.1
rrectness of i
t to the co
nform
spec
at
i
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in t
his
tact carrier (wedge) in the sliding door and a contract strip

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Note
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Removing:
key.
Remove door contact switch from B-pillar.
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Remove
spring clip -2- and remove microswitch -1-.
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p
Remove lower trim from B-pillar General body repairs, in

terior; Rep. gr. 70 ; Trim, insulation; Pillar trims; Removing and
installing lower B-pillar trim .
Installing:
3.3.2
rrectne
s
s
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f
i
t to the co
n
form
spec
atio
h re
n
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i
n
thi
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en
Release and disconnect connector from door contact switch

inside B-pillar.
Removing and installing rear right door

contact switch for sliding door or side
door
r
fo
ng
Note
The rear right door contact switch for sliding door or side door F7- is located in the bush (B-pillar), which is activated and deac
tivated by a wedge in the sliding door.
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Removal and installation of the rear right door contact switch

for sliding door or side door are carried out in the same way
as the removal and installation of the rear left door contact
switch for sliding door or side door page 330 .
3. Lights and controls in sliding doors
331
AG.

Lights and controls in the centre con

sole

compartment, page 332
4.1
Removing and installing buttons in cen

tre console storage compartment
Depending on equipment, the following buttons are installed in

AG. Volkswagen AG d
the centre console storage compartment:
agen
o
TCS and ESP button - E256 Fuel selection switch (petrol, gas) -
es n
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E395u
a
ss
Parking aid button - E266-
Park assist steering button - E581 Start/stop operation switch - E693Note
The procedure for removal and installation is the same for all but
tons in the centre console storage compartment and is therefore
described for just one button.
Removing:
key.
Prote
cted
by
332
AG.
Pull storage compartment out of centre console.
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Remove rubber mat from storage compartment.
rrectne
s
s
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f
i
t to the co
n
form
spec
atio
h re
n
wit
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Tyre pressure monitor display button - E492-

Release and disconnect connectors -arrow- from all built-in
buttons.
es, in part or in w
l purpos
hole
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Unlock locking lugs -arrows- and remove button from mount

ing frame.
rrectness of i
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spec
atio
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Installing:
thi
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4. Lights and controls in the centre console
333
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olkswagen AG
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in luggagedocom
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partment
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5.3 Removing and installing luggage compartment light switch

F5 , page 336
5.4 Removing and installing central locking switch in left wing
door F213 , page 336
5.5 Removing and installing rear door contact switches , page
336
5.6 Removing and installing rear lid release switch E165 ,
page 336
5.1
Removing and installing luggage com

partment light
5.1.1 Removing and installing luggage compartment light , ve

hicles with rear lid, page 334
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partment light , vehicles with rear lid
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5.1.1
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5.1.2 Removing and installing luggage compartment light , ve

hicles with rear wing doors, page 335
Note

(switches, covers, trim and so on), mask off areas in which tools
( removal wedge - VAS 3409- , screwdriver) are used to lever out
those components using commercially available masking tape.
Removing:
key.
334
rrectne
s
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f
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t to the co
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form
spec
atio
h re
n
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5.2 Removing and installing bulb for luggage compartment

light, page 335
or
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ce
5.1 Removing and

ss installing luggage compartment light , page
334

Lever out luggage compartment light -arrow- from luggage
compartment trim using removal wedge - VAS 3409- .

Installing:
5.1.2

partment light , vehicles with rear wing
doors
The procedure for removing and installing the luggage G

com
A . Volkswagen AG d
genis
a
partment light - W3- on vehicles with rear winglkdoors
the
oes
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same as that on vehicles with rear lid page
by 334 .
a
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Removing:
ed
ris
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bulb for lug
au
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s
gage compartment light
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5.2
Remove luggage compartment light page 334 .
rrectness of i
t to the co
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spec
atio
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n in
wit
Release locking lugs -1- and remove heat shield -2- from lens
of light.
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5. Lights and controls in luggage compartment
335
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Carefully lever bulb out of socket.
Bulb for luggage compartment light : glass base bulb 12 V, 6 W
Installing:
5.3

partment light switch - F5-
Luggage compartment light switch - F5- (vehicles with rear lid)

and left luggage compartment light switch - F357- / right luggage
compartment light switch - F358- (vehicles with rear wing doors)
are integral parts of corresponding rear lid/door locks and can
therefore not be renewed individually.
Replace rear lid lock cylinder General body repairs, exterior;
Rep. gr. 55 ; Rear lid; Removing and installing lock cylinder .
Renewing rear wing door lock General body repairs, exte
rior; Rep. gr. 55 ; Rear wing doors; Removing and installing
lower left lock .
5.4
Removing and installing central locking

switch in left wing door g-enF213AG. Volkswagen AG d
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exte
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y Vdoor - F213- is integral part
The central locking switch in left wing
db
ir se
of the rear wing door lock and ocannot
be renewed individually.
h
ut
un
le
Removing and installing rear door con

tact switches
The rear left door contact switch - F227- as well as the rear right
door contact switch - F226- is integral part of the rear wing door
lock and cannot be renewed individually.
Renewing rear wing door lock General body repairs, exte
lower left lock .
5.6
Removing and installing rear lid release

switch - E165-
The rear lid release switch - E165- is integral part of the rear wing
door lock and cannot be renewed individually.
AG.
Prote
cted
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336
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Replace rear lid lock cylinder General body repairs, exterior;

Rep. gr. 55 ; Rear lid; Removing and installing lock cylinder .
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
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Renewing rear wing door
ss lock General body repairs,
lower left lock .

AG. Volkswagen AG d
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interior
light
,
vehicles
as
of
s
s
Lights and controls in the roof trim

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hole
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6.1 Removing and installing front

06.07, page 337
6.2 Removing and installing bulb for front interior light , vehicles
as of 06.07, page 338
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
6.3 Removing and installing front interior light , driver side

reading light and front passenger reading light , page 338
6.4 Removing and installing bulb for front interior light,
page 340
6.5 Removing and installing bulb for front reading light,
page 341
6.6 Removing and installing left centre reading lamp and right
centre reading lamp , page 342
6.7 Removing and installing rear left interior light and rear right
interior light , page 342
6.8 Removing and installing bulbs for centre reading lights and
rear interior lights , page 343
AG.
Removing and installing front interior

light , vehicles as of 06.07
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6.10 Removing and installing light for vanity mirror,

page 345
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6.9 Removing and installing vanity mirror light , page 344
Note

Removing:
key.
6. Lights and controls in the roof trim
337

Carefully lever interior/reading light out of installation frame
using removal wedge - VAS 3409- or suitable screwdriver.
Release and disconnect electrical connector.
Installing:
Removing and installing bulb for front

interior light , vehicles as of 06.07
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Removing:
key.
Remove front interior light page 337 .
Remove cover on rear of interior light in -direction of arrow-.
Bulb for front interior light : festoon bulb 12 V, 10 W
Installing:
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Removing and installing front interior

light , driver side reading light and front
passenger reading light
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Prote
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Note

338
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6.3
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6.2
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or
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ac
a
ss

Carefully lever lens for interior/reading light out of installation

frame using removal wedge - VAS 3409- or suitable screw
driver.
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Undo screws -1- and release locking lugs -2-.
rrectne
s
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f
i
t to the co
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form
spec
atio
h re
n
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Removing:
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Installing:
339

6.4

interior light
Note
olkswagen AG
en AG. V
does
not
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When removing and installing components that are in view olkswag

V
un
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by
ed
risused to
tools ( removal wedge - VAS 3409- , screwdriver) are
o
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sa
s
masking tape.
es, in part or in w
l purpos
hole
ercia
, is n
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com
to gain access to the bulbs.
pe
rm
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d
There is no need to remove the interior light and reading lamp
r
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key.
Prote
cted
by
Bulb for front interior light : festoon bulb 12V, 10W

Installing:
340
AG.
Press contact plate -1- of light in direction of arrow and remove

festoon bulb -2- from bulb holder.
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driver.
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Removing:
ht
rig
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Co
t.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s


reading light
pe
rm
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Note
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6.5
es n
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l purpos
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ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

masking tape.
There is no need to remove the interior light and reading lamp
to gain access to the bulbs.
The procedure for removal and installation of bulbs for the
driver side reading light and the front passenger reading light
is the same and is therefore described for one bulb only.
do
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Removing:
key.
driver.
341

Carefully pull defective capless glass bulb -arrows- of the cor
responding reading light out of holder.
Bulb for front reading light : glass base bulb 12 V,
geW
es
wa5
Installing:
not
gu
ara
nte
eo
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c
ility
ab
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ce
6.6
rrectness of i
t to the co
nf
o
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m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
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t
a
itte
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f
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ng
Installation is carried out in
ks
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by
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ris
ho
t
u
reverseaorder
of removal.
ss
Removing and installing left centre read

ing lamp and right centre reading lamp
Removal and installation of the left centre reading light and the
right centre reading light are carried out in the same way as those
of the rear left interior light - W47- and the rear right interior light
- W48- page 342 .
6.7
Removing and installing rear left interior

light and rear right interior light
AG.

masking tape.
The procedure for removal and installation is the same for all
the rear interior lights and is therefore described for one light
only.
Removing:
key.
342
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Note
thi
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en

Lever interior light out of the roof trim -arrow-.

Installing:
Removing and installing bulbs for centre

reading lights and rear interior lights
The procedure for removal and installation of these bulbs is the

same and is therefore described for one light only.
Removing:
key.
Remove centre reading light page 342 or rear interior light
page 342 .
Pull cover -1- off light.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Note
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
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or
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f
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6.8
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es n
wage
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343
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Press contact plate -1- to one side and remove festoon bulb
-2- from bulb holder.
Bulb for centre reading lights and rear interior lights : festoon bulb
12 V, 5 W
Installing:
6.9
Removing and installing vanity mirror

light
Note

masking tape.
The procedure for removal and installation of the vanity mirror
lights on driver and front passenger sides is the same and is

therefore described for one light only.
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
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o
nl
f
e
ng
rrectness of i
t to the co
nf
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r
m
spec
atio
h re
n in
wit
Removing:
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AG. Volkswagen AG d
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Special tools and workshop equipment requiredby V
gu
ara
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ise
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Removal wedge - VAS 3409h
t
u
ra
a
c
s
s
key.
Carefully lever light out of roof trim using removal wedge - VAS
3409- or a screwdriver.
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by
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en
344

Installing:
Removing and installing light for vanity

mirror
Removing:
key.
Remove illuminated vanity mirror light page 344 .
Press contact plate -1- of light in direction of arrow and remove
festoon bulb -2- from bulb holder.
Bulb for vanity mirror light : festoon bulb 12 V, 5 W
Installing:
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
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f
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6.10
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AG. Volkswagen AG d
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345
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Prote
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by c
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Lights and controls in engine com

partment
7.1 Removing and installing bonnet contact switch ,

page 346
7.1
Removing and installing bonnet contact

switch
Note
The bonnet contact switch - F266- is integrated in the bonnet
lock and cannot be replaced as a single item.
If the bonnet contact switch - F266- is found to be defective,
the entire bonnet lock must always be replaced.
agen
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Prote
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by
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do
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fo
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n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
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un
le
ility
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346
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AG. Volkswagen AG d
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b
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Remove bonnet lock General body repairs,
exterior;
Rep.
nte
ise
r
o
gr. 55 ; Bonnet; Removing and installing
bonnet
lock;
Remov
eo
h
t
u
ra
a
ing .
c
s
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
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AG. Volkswagen AG d
agen
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Caddy
2004
u,aCaddy
2011
e
is
tee
r
ho
Electrical
system
Edition
10.2014
t
o
ra
au
c
ss
Other interior lights and controls
8.1
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
8.1 Removing and installing interior monitoring deactivation

switch and deactivation button for vehicle inclination sender ,
page 347
Removing and installing interior moni

toring deactivation switch and deactiva
tion button for vehicle inclination sender
Note
The interior monitoring deactivation switch - E267- and the
deactivation button for vehicle inclination sender - E360- are

located in the B-pillar trim on the driver side.
When removing and installing components that are in areas
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cted
by c
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AG.
deactivation switch/vehicle inclination sender deactivation

button has been modified and the function of the switch/button
has been changed from that of a rocker switch to that of a
single button switch.
ht
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py
Co
t.
On vehicles as of 06.2007, the design of the interior monitoring
do
c
um
en
on view (switches, covers, trims etc.), mask off areas in which

leverage tools ( removal wedge - VAS 3409- , screwdriver) are
used to lever out those components using commercially avail
able adhesive tape.

Removing:
key.
Carefully prise out the interior monitoring deactivation switch
- E267- and the deactivation button for vehicle inclination
sender - E360- using the wedge - VAS 3409- or a suitable
screwdriver.
8. Other interior lights and controls
347

Installing:
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348
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Cigarette lighter and 12 V socket
9.1 Removing and installing cigarette lighter U1 , page 349

9.2 Removing and installing 12 V socket, page 349
9.1
Removing and installing cigarette lighter

- U1-
All information regarding removal and installation of cigarette

lighters is available in the workshop manual Electrical system,
General information Electrical system, General information;
Rep. gr. 96 ; Cigarette lighters - U1- .
9.2
Removing and installing 12 V socket
9.2.1 Removing and installing 12 V socket, page 349

9.2.2 Removing and installing 12 V-socket (for accessories) in
centre of dash panel, page 349
9.2.1
Removing and installing 12 V socket

Puller - T40148-
es, in part or in w
l purpos
hole
ercia
, is n
m
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ot p
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or
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wit
The 12 volt sockets installed in the vehicle can be removed with

the help of the puller - T40148- without removal of the interior
equipment components. Sockets that are secured with a threaded
connection as well as sockets of a type that the puller does not fit
on to are exceptions.
All necessary information on cigarette lighters and 12 V sockets
can be found in the workshop manual Electrical system, General
information:
Removing and installing 12 V socket Electrical system,
General information; Rep. gr. 96 ; 12 V socket .
Removing and installing cigarette lighter Electrical system,
General information; Rep. gr. 96 ; Cigarette lighter - U1- .
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The 12 V-socket (for accessories) is installed in the upper centre

storage compartment of the dash panel.
ht
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Note
Removing and installing 12 V-socket

(for accessories) in centre of dash panel
thi
sd
o
cu
m
en
9.2.2
Prote
cted
by
9. Cigarette lighter and 12 V socket
349

Puller - T40148-
Removing:
key.
Remove upper storage compartment in centre of dash panel
General body repairs, interior; Rep. gr. 68 ; Compartments/
covers; Removing and installing upper storage compartment
in centre of dash panel .
Further removal of the socket is carried out, as for all other sock
ets, using puller - T40148- Electrical System, General Infor
mation; Rep. gr. 96 ; 12 V-socket .
Installing:
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350
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at
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10
Immobiliser
10.1 General description - immobiliser, page 351

10.2 Removing and installing immobiliser control unit ,
page 351
10.3 Removing and installing immobiliser reader coil ,
page 351
10.4 Removing and installing ignition key variable code trans
ponder, page 352
10.5 Adapting ignition keys to the immobiliser, page 352
10.6 Adapting ignition keys to the convenience system, page
352
10.1
General description - immobiliser

Note
tions
AG. Volkswagen AG d
The Caddy features a fourth-generation immobiliser.
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New features of the forth-generation immobiliser:
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It is no longer possible to adapt components
of other corporate
ut
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brands for use in Volkswagenssvehicles.
es n
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ua
ran
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or
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rrectness of i
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a
t
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wit
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hole
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, is n
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rm
itte
d
The ignition keys are preprogrammed with a base code on the

premises of the manufacturer. This base code contains a spe
cific manufacturer's code. The keys can be taught into a
vehicle only if programmed with the correct manufacturer's
mode.
The immobiliser is equipped with self-diagnosis, which makes
fault finding easier.
ing mode page 403 .
10.2
Removing and installing immobiliser

control unit
r
te o
iva
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rp
fo
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Renewing dash panel insert page 102 .
Prote
cted
by
The immobiliser reader coil - D2- is joined to the lock cylinder and
cannot be renewed individually.
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Removing and installing immobiliser

reader coil
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10.3
do
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The immobiliser control unit - J362- is integrated in the dash panel

insert. In the event of control unit failure, the complete dash panel
insert must be renewed.
AG.
Removing and installing lock cylinder page 362 .
10. Immobiliser
351

10.4
Removing and installing ignition key var

iable code transponder
Removing and installing the ignition key battery with remote

control General body repairs, exterior; Rep. gr. 57 ; Central
locking; Removing and installing battery for key with remote
control (folding) .
Removing and installing the radio container (transmission unit
for remote control central locking) for the ignition key Gen
eral body repairs, exterior; Rep. gr. 57 ; Central locking;
Removing and installing battery for key with remote control
(folding) .
Ignition key - variable code transponder:
The variable code transponder in the ignition key cannot be re
placed.
The ignition key must always be replaced if the variable code
AG. Volkswagen AG d
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transponder is defective.
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Note
ua
ran
tee
b
ed
ris
o
h
t
au
ss
the new ignition key must always be adapted to the immobil

iser page 352 .
If the radio container (transmission unit for remote controlled
central locking) of the ignition key is also replaced, it must be

adapted to the convenience system page 352 .
10.5
Adapting ignition keys to the immobiliser

Adapting ignition keys
10.6
Prote
cted
by
Immobiliser functions
Adapting ignition keys to the conven

ience system

Body
352
AG.
Immobiliser
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Electrical system
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If an ignition key is replaced or a further ignition key is required,

Convenience system
Functions of convenience system central control unit
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Adapting/checking convenience system central control unit J393-
10. Immobiliser
353
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11
Anti-theft alarm (ATA)
11.1 General description - anti-theft alarm system (ATA), page

354
11.2 Removing and installing interior monitoring deactivation
switch and deactivation button for vehicle inclination sender ,
page 355
11.3 Removing and installing interior monitoring sensor , page
355
11.4 Removing and installing vehicle inclination sender , page
356
11.5 Removing and installing central locking and anti-theft
alarm system aerial , page 356
11.6 Removing and installing alarm horn , page 357
11.7 Reading alarm sources of anti-theft alarm, page 357
11.1
General description - anti-theft alarm

system (ATA)
Note
n AG. Volkswagen A
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wage and Fitting loca does n
Current flow diagrams, Electrical fault finding
ot g
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tions
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atio
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wit
The anti-theft alarm system is equipped with self-diagnosis, which

makes fault finding easier.
ing mode page 403 .
Note
If the anti-theft alarm has been triggered, the alarm source stored
in the convenience system central control unit - J393- can be read
page 357 .
Activating anti-theft alarm:
The anti-theft alarm system is switched on automatically when the

vehicle is locked. The anti-theft alarm is then immediately primed.
Prote
cted
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To prevent the anti-theft alarm system from triggering alarms un

necessarily, make sure to close all windows and doors completely
before locking the vehicle.
AG.
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354
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es, in part or in w
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tho
The functions of the ATA are integrated
into the convenience
au
s
system central control unit - J393.
s

Deactivating anti-theft alarm:
The anti-theft alarm is deactivated on unlocking the vehicle
with the remote control unlocking button or
when the ignition is switched on.
Unlock the vehicle mechanically (emergency open):
Open driver's door.
The anti-theft alarm system remains active, although no alarm is
triggered.
Switch ignition on within 15 seconds.
Note
If ignition is not switched on, alarm will trigger after 15 seconds.

When the ignition is switched on, the electronic immobiliser de
tects a valid ignition key and deactivates the anti-theft alarm.
11.2

toring deactivation switch and deactiva
tion button for vehicle inclination sender
Removing and installing interior monitoring deactivation

switch - E267- and deactivation button for vehicle inclination
sender - E360- page 347
11.3

toring sensor
Note
. Volkswagen AG
gen AG
does
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The interior monitoring sensor is installed in the moulded headVolkswa

y
liner -arrow-.
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Removing:
ri
ho
ut
a
ss
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
key.
Using a small screwdriver on the right-hand side of the interior

monitoring sensor, open the spring clips -arrow- and unclip the
interior monitoring sensor from the headliner.
Release and disconnect electrical connector on interior mon
itoring sensor.
Installing:
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11. Anti-theft alarm (ATA)
do
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355
Prote
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AG. Volkswagen AG d
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Caddy 2004 , oCaddy
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Electrical system
- Edition 10.2014
ed
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Removing and installing vehicle inclina

tion sender
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
On vehicles as of model year 2011, the vehicle inclination
sender described below is no longer being used. The vehicle

inclination sender on vehicles as of model year 2011 is inte
grated into the anti-theft alarm sensor - G578- .
The vehicle inclination sender - G384- -arrow- is located on
the right beneath the dash panel, behind the front passenger's
airbag.
The anti-theft alarm system must be deactivated before vehi
cle inclination sender - G384- is removed page 354 .
key.
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Unscrew securing bolts -1- and remove vehicle inclination

sender - G384- from support.
AG.
Prote
cted
by
Release connector -2- and disconnect it from vehicle inclina

tion sender - G384- .
Installing:
11.5
Removing and installing central locking

and anti-theft alarm system aerial
Note
tions
The central locking and anti-theft alarm system aerial - R47- is
routed from the convenience system central control unit - J393to the A-pillar (driver side) in the main wiring harness.
Note
The aerial cannot be repaired as this would adversely affect
the reception quality.
In the event of damage, it is necessary to replace the central
locking and anti-theft alarm system aerial - R47- .
356
do
c
um
en
r
te o
iva
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rp
fo
g
n
Removing:
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Note
ility
ab
y li
an
pt
ce
11.4
ris
tho
u
a
ss

11.6
Removing and installing alarm horn

Note
The alarm horn - H12- is installed on the left below the plenum
chamber cover.
On right-hand drive vehicles, the alarm horn - H12- is installed
in the mirror-image position on the right-hand side.
The alarm horn - H12- can be checked using final control di
agnosis for convenience system central control unit - J393- .

Note
ility
ab
y li
an
pt
ce
Removing:
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
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or
nl
f
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n
If the alarm horn - H12- is removed,

must be deactivated page 354 .
AG. Volkswagen AG d
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the anti-theft
alarm
system
eo
h
ut
ra
a
c
s
s
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
key.
page 108 .
Release connector -2- and disconnect it from alarm horn H12- .
Unscrew securing nuts -1-.
Remove alarm horn - H12- from vehicle.

Installing:

Tighten securing nuts for alarm horn to 9 Nm.
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ht
rig
py
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Reading alarm sources of anti-theft

alarm
do
c
um
en
11.7

11. Anti-theft alarm (ATA)
357

Body
Convenience system
AG. Volkswagen AG d
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358
rrectne
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s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
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or
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t
a
itte
v
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p
ility
ab
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Reading J393 alarm sources of anti-theft alarm

12
Ignition/starter switch and lock cylin

der
12.1 Removing and installing ignition/starter switch,

page 359
12.2 Checking ignition/starter switch, page 361
AG. Volkswagen AG d
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12.3 Removing and installing lock cylinder, page
Vol 362

page 366
y
db
isehousing,
r
steering lock
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s
s
not
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hole
ercia
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a
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riv
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12.1
ility
ab
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an
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ce
12.5 Removing and installing ignition key withdrawal lock sol

enoid, page 367
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Removing and installing ignition/starter

switch
12.1.1 Removing and installing ignition/starter switch, vehicles

up to model year 2010, page 359
12.1.2 Removing and installing ignition/starter switch, vehicles
as of model year 2011, page 360
12.1.1

switch, vehicles up to model year 2010
Caution
AG.
Prote
cted
by
Release and disconnect connector -2- at ignition/starter switch

-1-.
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Removing:
do
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page 3 .
Release ignition/starter switch with a small screwdriver

-arrows-.
Remove ignition/starter switch -1- from steering lock housing.
Installing:
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.
Push ignition/starter switch into steering lock housing until it
engages audibly.
12. Ignition/starter switch and lock cylinder
359

Insert ignition key in lock cylinder and turn to Drive position.
Note
The key must be in the Drive position.

Positions for key in lock cylinder:
1 - Position Stop
2 - Position Drive
3 - Position Start

switch, vehicles as of model year 2011

Release and disconnect electrical connector -2- at ignition/
starter switch -1-.
Manufacturer Kostal:
Expose hole -2- under seal -3-.
AG.
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by
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360
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Using a small screwdriver, release cover -1- in direction of

-arrow- and remove.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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en
Removing:
ole,
cial p
is n
mer
m
ot p
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or
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a
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12.1.2
es n
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or
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ss
ility
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un
le
Install components in reverse order of removal.

Release ignition/starter switch using 2 small screwdrivers
-arrows-.
Pull ignition/starter switch -1- out of steering lock housing.
Installing:
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.
Push ignition/starter switch into steering lock housing until it
engages audibly.
Insert ignition key in lock cylinder and turn to position Drive.
Note
The key must be in the Drive position.

1 - Position Stop
2 - Position Drive
3 - Position Start
oes
not
gu
ara
nte
eo
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Checking ignition/starter switch
rrectness of i
t to the co
nform
spec
a
t
i
h re
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n in
wit
thi
s
es, in part or in w
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12.2
wa
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. Volkswagen AG
Install all components in reverse order of removal.
gen AG
d

Body
Electrical system
Diagnostic capable systems
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Ignition/starter switch
do
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Switch button
r
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iva
r
rp
fo
g
n
361

12.3
Removing and installing lock cylinder
12.3.1 Removing and installing lock cylinder, vehicles up to

model year 2010, page 362
12.3.2 Removing and installing lock cylinder, vehicles as of
model year 2011, page 364
12.3.1
Removing and installing lock cylinder,

vehicles up to model year 2010
Caution

hered to page 3 .
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.
Removing:
Remove driver airbag General body repairs, interior; Rep.
gr. 69 ; Airbag; Removing and installing driver airbag; Re
moving .
es n
ot g
ua
ran
tee
t
or
u
ac
a
General
ss body repairs, interior;
wage Rep.
Remove steering wheel Running gear, axles, steering;
olks
V
y
gr. 48 ; Assembly overview - steering wheel;d bRemoving and
installing steering wheel: Removing . horise
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362
ht
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The immobiliser reading coil is secured to the lock cylinder and

rrectne
s
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o
f
i
t to the co
n
form
spec
atio
h re
n
wit
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Note
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Remove steering column trim


olkswagen AG
en AG. V
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1 - Position Stop
olks
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ed
2 - Position
ris Drive
ho
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rrectness of i
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spec
atio
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wit
es, in part or in w
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a
3 - Position
Start
ss
Note
thi
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m
en
For reasons of clarity, the lock cylinder is shown in the following

illustration without ignition key.
Insert a piece of steel wire (approx. 1.2 mm in diameter) into
hole -arrow- next to ignition key.
ht
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Using steel wire -2- release locking lever -3- of lock cylinder
-1- -arrow-.
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AG.
Prote
cted
by
Pull lock cylinder together with inserted steel wire out of steer
ing lock housing in direction of arrow.
363

Release and disconnect connector of reader coil -A- in
Installing:
AG. Volkswagen AG d
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cylinder
until
it
ap
s
s
Insert lock cylinder -1- into steering lock housing.

Note
The connection for the reader coil of the immobiliser must be in

serted in the steering lock housing guide.
Pull steel wire -2- out of lock cylinder -1- and check lock cyl
inder is seated correctly in the steering lock housing.
Fit connector onto immobiliser reader coil and engage it.
Prote
cted
by
Caution

hered to page 3 .
der.
Removing:
364
AG.
Removing and installing lock cylinder,

vehicles as of model year 2011
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12.3.2
ht
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Ensure that wiring harness of reader coil is properly routed

over lock cylinder -arrows-.
rrectne
s
s
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f
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t to the co
n
form
spec
atio
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n
wit
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Insert steel wire -A- through hole in lock

pears in securing lever hole -B- -arrow-. This is the release
position of the securing lever.
Note
For reasons of clarity, the steering column switch module, coil
connector and steering wheel are not shown in the illustration.

There is no need to remove the components in order to remove
the lock cylinder.
The immobilizer reading coil is secured to the lock cylinder and
For reasons of clarity, the ignition key is not shown in the fol
lowing illustrations.
The hole may be 180 further than shown in the illustration.
This does however not affect the procedure for removing and
installing.
Prote
cted
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2 - Position Drive
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1 - Position Stop
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Insert ignition key in lock cylinder and turn to position Drive.
rrectne
s
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f
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t to the co
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form
spec
atio
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AG. Volkswagen AG d
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h
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c
ss
3 - Position Start
Note
For reasons of clarity, the lock cylinder is shown in the following

illustration without ignition key.
Insert a piece of steel wire (approx. 1.2 mm in diameter) in hole
-arrow- next to ignition key.
-1- -arrow-.
Pull lock cylinder -1- out of steering lock housing.
365

Release and disconnect connector -arrow- on immobiliser
reader coil.
Installing:
Note
For reasons of clarity, the ignition key is not shown in the following
illustration.
Insert ignition key in lock cylinder -1- and turn to position
Drive.
-1- -arrow-.
Connect connector to immobiliser reader coil and engage it.
Insert lock cylinder -1- into steering lock housing.
Note
es n
wage
s
k
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The connection for the reader coil of the immobilizer must be in y Vo
ua
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ran
serted in the steering lock housing guide.
ir se
tee
o
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or
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ac
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s
Pull steel wire -2- out of lock cylinder -1- and check slock
cyl
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
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erm
o
e
t
a
itte
riv
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f
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n
ility
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pt
ce
inder is seated correctly in the steering lock housing.
Install all components in reverse order of removal.
Removing and installing steering lock

housing
Note
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
12.4
Steering lock housing is removed together with steering column

switch module base.
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366

Caution

hered to page 3 .
der.
Removing:
Remove steering column switch module base page 269 .
12.5
Removing and installing ignition key

withdrawal lock solenoid
12.5.1 Removing and installing ignition key withdrawal lock

solenoid, vehicles up to model year 2010, page 367
AG. Volkswagen A
G do
gen key withdrawal
es n
12.5.2 Removing and installing
lock
swa
kignition
ot g
Vol 2011, page 368
y
solenoid, vehicles as of model
year
ua
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Removing
and installing ignition key
ss
withdrawal lock solenoid, vehicles up to
model year 2010
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Note
The ignition key withdrawal lock solenoid - N376- is located
very close to the ignition starter key.
To remove ignition key on vehicles with an automatic gearbox,
always move selector lever to position P first then switch off

ignition. Otherwise the ignition key withdrawal lock solenoid N376- will inhibit the removal of the ignition key.
Removing:

Release catch -2- with a suitable screwdriver.
Prote
cted
by c
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The connector will be disconnected automatically.

agen
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Installing:
ht
rig
py
Co
t.
Pull ignition key withdrawal lock solenoid - N376- -1- in direc

tion of arrow out of its mounting.
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
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erm
o
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t
a
itte
riv
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n
12.5.1
an
tee
or
ac

AG.
Note
After connecting the battery, carry out final control diagnosis to

activate the ignition key withdrawal lock solenoid page 271 .
367

12.5.2
Removing and installing ignition key

AG. Volkswagen AG d
oes
withdrawal lock solenoid, vehicles as ofVolkswagen
not
gu
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b
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model year 2011
e
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Note
tho
au
s
s
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
very close to the ignition starter key.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
The ignition key withdrawal lock solenoid - N376- is located

To remove ignition key on vehicles with dual clutch gearbox
(DSG), always move selector lever to position P first, then

switch off ignition. Otherwise the ignition key withdrawal lock
solenoid - N376- will inhibit the removal of the ignition key.
Removing:

Release catch -2- using a suitable screwdriver.
The connector will be disconnected automatically.
368
Prote
cted
by
After connecting the battery, carry out final control diagnosis to

activate the ignition key withdrawal lock solenoid page 283 .
AG.
Note
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Installation is carried out in the reverse order. When installing

observe the following:
ht
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Co
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Installing:
do
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iva
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fo
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n
Pull ignition key withdrawal lock solenoid - N376- -1- in direc

tion of arrow out of its mounting.

97
Wiring
Relay carriers, fuse holders, E-boxes
1.1 Overview of fitting locations - relay carriers, fuse holders,

E-boxes, page 369
1.2 Removing and installing fuse holder on left beneath dash
panel, page 370
1.3 Removing and installing relay carrier on left of dash panel,
page 370
1.4 Removing and installing relay carrier on onboard supply
control unit, page 371
1.5 Removing and installing E-box on left side of engine com
partment, page 374
1.1
AG. Volkswagen AG d
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not
olks locations - relay carriers,
Overview of bfitting
fuse holders, E-boxes
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carrier
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t
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wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
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com
2 - Relay carrier
Installed on bracket on
driver side under dash
panel.
relay carrier
page 370
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do
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3 - Relay carrier on onboard

supply control unit
Installed on bracket on
onboard supply control
unit.
relay carrier, vehicles up
to and including model
year 2010 page 371
relay carrier, vehicles
from model year 2011
page 373
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Prote
cted
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4 - Fuse holder C - SC Installed on bracket on

driver side under dash
panel.
fuse holder
page 370
or
ac
ility
ab
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an
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1 - Auxiliary relay
gine compartment
Installed under E-box.
5 - Fuse holder B - SB Installed on left of E-box

in engine compartment.
page 374 .
6 - Fuse holder A - SA Installed on left-hand side of E-box in engine compartment.
1. Relay carriers, fuse holders, E-boxes
369

1.2
Removing and installing fuse holder on

left beneath dash panel
Caution

page 3 .
Removing:
es n
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o
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Remove storage compartment on driver's side Generaled by V
ran
s
i
tee
r and
body repairs, interior; Rep. gr. 68 ; Compartments, covers
o
h
t
or
u
trim
ac
a
ss
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
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c
erm
or
e
t
a
itte
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f
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ng
Installing:
ility
ab
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pt
ce
Undo and remove bolts -arrows- and pull off fuse holder -1downwards from bracket.
1.3
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Removing and installing relay carrier on

left of dash panel
Caution
Prote
cted
by
Release catches -arrows A-.

Twist out relay carrier -1- under locking lugs -arrows B-.
Pull built-in relays out of relay carrier.
Release and disconnect connectors on rear of relay carrier
-1-.
Remove relay carrier -1- from vehicle.
Installing:
370
Rep. gr.97 - Wiring
AG.
Remove storage compartment on driver's side General

body repairs, interior; Rep. gr. 68 ; Compartments, covers and
trim
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Removing:
thi
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en

page 3 .

1.4

onboard supply control unit
1.4.1 Removing and installing relay carrier on onboard supply

control unit, vehicles up to model year 2010, page 371
1.4.2 Removing and installing relay carrier on onboard supply
control unit, vehicles from model year 2011, page 373
1.4.1

onboard supply control unit, vehicles up
to model year 2010
Note
The onboard supply control unit - J519- and the relay carrier
attached to it in left side of dash panel form one unit and cannot
be separated.
. Volkswagen AG
If the relay unit on the onboard supply control unit on thewaleft
gen AG
doe
ks
is to be replaced, the procedure for reading out theycodes
Vol
b
d
stored in the onboard supply control unit - J519-isemust always
r
be carried out
ho
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a
2.1.3 Coding onboard supply control unit
ss , page 380 .
pe
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itte
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Removing:
s no
t gu
ara
nte
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c
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
key.
Remove fuse holder on the left in dash panel page 370
Note
The fuse holder does not have to be removed completely. You

only have to loosen it and, if necessary, place it to one side.
do
c
um
en
ht
rig
py
Co
t.
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te o
iva
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fo
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Press lugs on bracket apart -arrows- and pull relay carrier

-1- out of holder as far as the wire lengths allow.
agen
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AG.
371
Prote
cted
by
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Push locking bar -1- into OPEN position -arrow A-.
Release locking lugs -arrows B- of connectors -2- and pull
connectors off relay carrier on onboard supply control unit on
left of dash panel.
Note
The number of connectors can deviate from that shown in the
es n
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o
yV
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b
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ran
The connectors for the control unit and relay carrier attached
ir se
tee
o
h
t
to the onboard supply control unit, on left of dash panel cannot
or
u
ac
a
be pulled off until the locking bars have been placed inss the
illustration depending on the vehicle equipment level.
ility
ab
y li
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pt
ce
OPEN position.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
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or
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n
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
To gain access to rear connectors, pull relay carrier secured

to onboard supply control unit, on left of dash panel, out of
retainer as far as wiring allows.
Push locking bar -1- into OPEN position -arrow-.
Note
The number of connectors can deviate from that shown in the
illustration depending on the vehicle equipment level.
The connectors for the control unit and relay carrier attached
to the onboard supply control unit, on left of dash panel cannot

be pulled off until the locking bars have been placed in the
OPEN position.
The locking catches cannot be placed in the CLOSED posi
tion until all connectors are fitted correctly.
After new control unit has been installed, it must be coded
page 380 .
372
Rep. gr.97 - Wiring
Prote
cted
by
Note
AG.

agen
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Installing:
ht
rig
py
Co
t.
Pull onboard supply control unit - J519- and relay carrier on

onboard supply control unit on the left in the dash panel out of
the holder.
do
c
um
en
Release all connectors and disconnect them from onboard

supply control unit - J519- .

1.4.2

onboard supply control unit, vehicles
from model year 2011
Note
The relay carrier on the onboard supply control unit is clipped
under the onboard supply control unit and can be removed.
The following illustrations show removal on a LHD vehicle.
Removal and installation in an RHD vehicle are performed us

ing the corresponding mirror-image procedure.
Removing:
G. Volkswage
n AG d
A
agen all electrical loads,
Switch off ignition
and
oesand pull out ignition
ksw
not
l
o
V
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key.
by
a
d
ise
ran
Remove fuse carrier from holder and allow to hang.
Press the two catches of the onboard supply control unit -1and -2- in -direction of arrow-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
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p
or
nl
f
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g
n
Undo screws -arrows- holding fuse carrier in place.
ility
ab
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an
pt
ce
tee
r
Remove
body
ho storage compartment on drive's side General
or
ut
adriver's
a
repairs,
interior;
Rep.
gr.
68
;
Storage
compartment
on
c
s
s
side; Removing and installing .
do
c
um
en
Remove onboard supply control unit together with relay carrier

from holder.
ht
rig
py
Co
t.
agen
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Vo
by
AG.
Prote
cted
by c
o
p
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gh
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C
op
yi
Press the two catches -arrows- and pull relay carrier off on
board supply control unit.
Release and disconnect all connectors from relay carrier.
Installing:
Installation is carried out in the reverse sequence.
373

1.5
Removing and installing E-box on left

side of engine compartment
Note
One of two different E-boxes are fitted depending on the level of

equipment (high or low versions). The following illustration show
the High version. Removing and installing the Low version is
performed in the same manner.
Caution

page 3 .
Removing:
Only for vehicles up to 05.2004
Release catches in -arrows- and remove lid of E-box -1- up
wards.
agen
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by
AG.
Prote
cted
by c
o
p
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t.
C
op
yi
Rep. gr.97 - Wiring
thi
sd
o
cu
m
en
374
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
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an
pt
ce
AG. Volkswagen AG d
agen
oes
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not
l
o
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by
ara
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is
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h
ut
ra
a
c
s
s
ht
rig
py
Co
t.
Only for vehicles as of 05.2004

Push locking bar -1- in -direction of arrow- and remove E-box
cover -2- upwards.
Volkswa
AG.
agen
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Continued for all vehicles
Vol
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
ss
y
db
ise
r
tho
au
gen AG
does
not
gu
ara
nte
eo
ra
c
Remove hexagon nuts -1-.

Open -arrows- covers -2- of cable guides on E-box.
Remove wiring from wiring guides.
thi
sd
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cu
m
en
Remove wires from connecting bolts.
ht
rig
py
Co
t.
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Vo
by
AG.
Prote
cted
by c
o
p
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C
op
yi
Remove central securing bolt -arrow- from E-box -1-.

Note
When central securing bolt -arrow- is unscrewed, E-box -1- is

pushed upwards off bracket of E-box.
Pull E-box -1- upwards away from bracket of E-box.
375

AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
In order to remove theut flat contact housing -1- on vehicles with
ra
a
c
s
diesel engine, the air
filter
housing,
the
battery
and
the
battery
s
Note
Undo and remove bolts -arrows- of battery tray -1-.

Remove battery tray -1- from vehicle.
ht
rig
py
Co
t.
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AG.
Prote
cted
by
c
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p
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C
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yi
Press tabs apart on bracket of E-box -arrows B- and slide flat

contact housing -1- sideways -arrow A- out of bracket of Ebox.
Press tabs apart on bracket of E-box -arrows C- and slide flat
contact housing -2- forwards -arrow D- out of bracket of E-box.
376
Rep. gr.97 - Wiring
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
Remove battery page 6 .
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Remove air filter housing if necessary (only in the case of ve

hicles with diesel engine).
ility
ab
y li
an
pt
ce
tray must be removed first.

Undo nuts -arrows- from bracket of E-box -1-.
Note
The installation of an additional relay carrier depends entirely on

the vehicle equipment.
Pull bracket of E-box -1- upwards off stud bolts as far as length
of relay carrier cables allows.
Unclip relay carrier -1- sideways out of bracket of E-box -2-.

Remove bracket of E-box -2- from vehicle.
Installing:

Tighten M5 securing nuts -1- to 4 Nm.
Tighten M6 securing nuts -1- to 6 Nm.
Vehicles up to 05.2004
ht
rig
py
Co
t.
Finally, ensure that the E-box cover is engaged correctly

-arrows-.
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377

Fit cover -2- onto E-box and push locking bar -1- in
-direction of arrow- until cover -2- engages.
Note
Finally, ensure that the E-box cover -2- is engaged correctly.
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Rep. gr.97 - Wiring
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Control units
2.1 Removing and installing onboard supply control unit , ve

2.2 Removing and installing onboard supply control unit , ve
2.3 Removing and installing data bus diagnostic interface ,
page 387
2.4 Removing and installing convenience system central con
trol unit , page 389
2.5 Removing and installing special vehicle control unit , page
392
2.1
Removing and installing onboard supply

control unit , vehicles up to model year
2010
2.1.1 General description - onboard supply control unit , page

379
2.1.2 Removing and installing onboard supply control unit ,
page 380
2.1.3 Coding onboard supply control unit , page 380
2.1.4 Adapting headlight washer system, page 381
2.1.1
General description - onboard supply

control unit
Note
The onboard supply control
unit - J519- and the relay carrier
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attached to it in leftlkside
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procedure
c
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2.1.3 Coding onboard supply control unit , page 380 for
reading the codes stored in the unit must always be carried
out.
es, in part or in w
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tions
The onboard supply control unit - J519- has the following equip
ment-specific functions in the vehicle:
Electrical load management
Exterior light control
Rear window wiper
Heated rear window
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Ambient lighting
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Interior light control
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Turn signal control
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nform
spec
a
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wit
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s
2. Control units
379
AG.
olkswagen AG
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Electrical system - Edition
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Fuel pump presupply

Alternator stand-by
Horn
Some of the above mentioned functions can be adapted:

Adapt heating function switch-off time for exterior mirrors
Adapt heating function switch-off time for rear window
Adapt lane change flashes
Adapting footwell light dimmer value
Adapt footwell dimmer value and lighting
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It depends on the fitted optional equipment whether or not the
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above-mentioned adaptations can be carried out.
AG.
Lane-change signalling, comfort signalling, or tap signal
ling means, one touch of the turn signal lever will activate the
turn signals (1 to 5 times) (turn signal cycles).

ing mode page 403 .
2.1.2

control unit
Note
If the onboard supply control unit - J519- is to be renewed, the

procedure
2.1.3 Coding onboard supply control unit , page 380 for read
ing the codes stored in the unit must always be carried out.
The removal and installation procedure of the onboard supply
control unit - J519- is the same as that of the relay carrier on on
board supply control unit, on left of dash panel page 371 .
2.1.3
Coding onboard supply control unit

380
Rep. gr.97 - Wiring
ht
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Note
r
fo
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Adapt headlight washer system page 381
rrectne
s
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form
spec
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Dimmers, instrument lighting
or
ac

Body
Electrical system
Coding control unit
2.1.4
Adapting headlight washer system
The active time of the headlight washer system can be variably

adjusted to between 0 and 12.75 seconds.
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capable systems
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Adapting headlight washer system
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2. Control units
381
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2.2

control unit , vehicles as of model year
2011
2.2.1 General description - onboard supply control unit, page

382
2.2.2 Removing and installing onboard supply control unit,
page 384
2.2.3 Coding onboard supply control unit J519 , page 385
2.2.4 Adapting onboard supply control unit , page 385
2.2.5 Onboard supply control unit J519 final control diagnosis,
page 386
2.2.1
General description - onboard supply

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procedure
2.2.3 Coding onboard supply control unit J519 ,
page 385 for reading the codes stored in the unit must be
carried out first.
rrectness of i
t to the co
nform
spec
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After renewing onboard supply control unit - J519- , the re
maining functions of the onboard supply control unit, such as

immobilizer, anti-theft alarm, entry and start authorisation,
tyre pressure monitor and the central locking system keys
must also be adapted (depending on equipment).
Start by adapting the immobiliser and continue, in any se
quence, with the further functions (dependent on equipment

level of vehicle) of the onboard supply control unit - J519- .
Self-study programme No. 423 ; The Golf 2009
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Operating manual
The onboard supply control unit - J519- controls the following

functions in the vehicle:
AG.
Electrical load management

Exterior light control
Turn signal control
Automatic wipe/wash, windscreen and rear window
Headlight washer system
Rain/light sensor
Heated windscreen and rear window
Interior light control
Terminal control
Dimmers, instrument lighting
382
Rep. gr.97 - Wiring
ht
rig
py
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tions
do
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Fuel pump presupply
Alternator stand-by
Horn
Hazard warning light
Release control
Control of the central locking system
Actuation of the front and rear door control units
Activation of the rear lid unlocking function
Activation of the fuel filler flap unlocking function
Activation of the anti-theft alarm (ATA)
Activation of the immobiliser
Activation of the entry and start authorisation
The following functions can be adapted page 385 :
Adapting turn signal cycles for lane change flash
Adapting automatic unlocking on removing ignition key
Adapting automatic locking at 15 km/h
Adapting confirmation of convenience closing
Deactivating factory mode
Adapting convenience operation via remote control
Adapting visual feedback when locking
ility
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Note
es, in part or in w
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Adapting remote control key
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rrectness of i
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at
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his
The onboard supply control unit - J519- features self-diagnosis to

facilitate fault finding.
ing mode page 403 .
do
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rig
py
Co
t.
2. Control units
383
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Volkswagen AG
Removing and installing onboard
AG.supply
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2.2.2
rrectness of i
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nform
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at
i
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in t
his
procedure
2.2.3 Coding onboard supply control unit J519 ,
carried out first.
The following illustrations show removal on a LHD vehicle.
Removal and installation of onboard supply control unit on an

RHD vehicle are performed using the corresponding mirrorimage procedure.
Removing:
key.
AG.
Press the two catches of the onboard supply control unit -1and -2- in -direction of arrow-.
Remove onboard supply control unit together with relay carrier
from holder.
384
Rep. gr.97 - Wiring
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Remove fuse carrier from holder and allow to hang.
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Unscrew securing bolts -arrows- from fuse carrier.
do
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Remove storage compartment on drive's side General body

repairs, interior; Rep. gr. 68 ; Storage compartment on driver's
side; Removing and installing .

Press the two catches -arrows- and pull relay carrier off on
board supply control unit.
Release and fold up locking bar -arrows- and disconnect all

connectors from onboard supply control unit.
Installing:
Installation is carried out in the reverse sequence.

Body
Electrical system

Functions
Coding onboard supply control unit online

r
fo
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Adapting onboard supply control unit

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The following functions can be adapted:
Prote
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Adapting automatic locking at 15 km/h
AG.
Adapting automatic unlocking on removing ignition key
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Adapting turn signal cycles for lane change flash
ht
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Co
t.
2.2.4
rrectne
s
s
o
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i
t to the co
n
form
spec
atio
h re
n
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i
n
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Coding onboard supply control unit J519-
ility
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2.2.3
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Adapting confirmation of convenience closing

Deactivating factory mode
Adapting convenience operation via remote control
2. Control units
385

Adapting visual feedback when locking
Adapting remote control key
Body
Electrical system
Functions
2.2.5
Onboard supply control unit - J519- final

control diagnosis
The following components and/or functions can be checked by

the final control diagnosis for the onboard control unit:
Left headlight dipped beam bulb - M29- and right headlight

dipped beam bulb - M31 Left daytime running light bulb - L174- and right daytime run
ning light bulb - L175 Left headlight main beam bulb - M30- and right headlight main
beam bulb - M32 Left fog light bulb - L22- and right fog light bulb - L23 Right reverse light bulb - M17- or left reverse light bulb - M16 Left brake light bulb - M9- or right brake light bulb - M10- and
additional brake light bulb - M25 Rear left fog light bulb - L46- and rear right fog light bulb - L47ht
rig
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Co
t.
Front left turn signal bulb - M5- and rear left turn signal bulb M6agen
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Front right turn signal bulb - M7- and rear right turn signal bulb
- M8AG.
Number plate light - X Dimmed interior light

Instrument lighting of all keys and switches and the dash panel
insert
Terminal 30 voltage supply relay - J317 LED heated rear window / heated rear window
LED heated exterior mirrors / heated exterior mirrors
Release of sliding/tilting sunroof
386
Rep. gr.97 - Wiring
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Left sidelight bulb - M1- , Right sidelight bulb - M3- , Left tail
light bulb - M4- and Right tail light bulb - M2-
do
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l purpos
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on the fitted equipment options.
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Whether the components
named
below
can
be
checked
depends
c
s
s

Release of seat heating
Fuel pump relay - J17 Headlight washer system relay - J39- and headlight washer
system pump - V11 Windscreen wipers
Wiper module change direction point
Washer pump - V5 Dual tone horn relay - J4- , treble horn - H2- and bass horn H7 Bulb for left static cornering light - M51- and right static cor
nering light - M52 Luggage compartment lock
Connect vehicle diagnostic
Electrical
system, Gen
wag
en AG
G. Volks
Atester
does
agen97 ; Vehicle diagnosis,
wgr.
eral information; Rep.
testing and
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information systems;
Connecting vehicle diagnostic
db
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Select Guided
fault finding in vehicle diagnostic tester e.or
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Body
es, in part or in w
l purpos
hole
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, is n
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ot
com

Functions
Onboard supply control unit final control diagnosis
2.3
Removing and installing data bus diag

nostic interface
2.3.1 General description - data bus diagnostic interface ,

page 387
r
te o
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rp
fo
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n
2.3.3 Renewing data bus diagnostic interface , page 389
General description - data bus diagnos

tic interface
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2.3.1
do
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2.3.2 Removing and installing data bus diagnostic interface ,

page 388
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Electrical system
If the data bus diagnostic interface - J533- is to be renewed,
the procedure
2.3.3 Renewing data bus diagnostic interface , page 389
for reading the codes stored in the unit must be carried out
first.
Current flow diagrams, Electrical fault finding and Fitting lo
cations
2. Control units
387

The data bus diagnostic interface - J533- (Gateway) is designed
as a separate control unit. It is responsible for the following in the
vehicle:
Data exchange between powertrain CAN data bus, conven
ience CAN data bus and infotainment CAN data bus.
Transfer of diagnostic data from the CAN bus to the diagnosis
CAN data bus and vice versa, so that data can be used by
the vehicle diagnostic tester .
The data bus diagnostic interface - J533- is equipped with selfdiagnosis, which makes fault finding easier.
olkswagen AG
en AG. V
ag
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Vol Vehicle
For fault finding, use the systems described in chapter
by
d
e
diagnosis, testing and information system in Guided
Fault Find
ris
tho
ing mode page 403 .
u
a
ss
Removing and installing data bus diag

nostic interface
es, in part or in w
l purpos
hole
ercia
, is n
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m
ot p
o
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erm
or
e
t
a
itte
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f
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ng
rrectness of i
t to the co
nf
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spec
atio
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n in
wit
Note
ility
ab
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2.3.2
does
not
gu
ara
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ra
c
If the diagnosis interface for data bus - J533- is to be replaced,

the
2.3.3 Renewing data bus diagnostic interface , page 389 pro
cedure must always be carried out for reading the codes stored
in the unit.
Removing:
key.
Release connector -2- and pull it off data bus diagnostic inter
face - J533- -1-.
Prote
cted
by
388
Rep. gr.97 - Wiring
AG.
Installing:
agen
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Remove data bus diagnostic interface - J533- from bracket.
ht
rig
py
Co
t.
Press together -arrows- securing pins -1- and push them up

wards out of holes.
thi
sd
o
cu
m
en
Remove cover, footwell, driver's side General body repairs,

interior; Rep. gr. 68 ; Compartments, covers and trim

2.3.3
Renewing data bus diagnostic interface

Body
Electrical system
Data bus diagnostic interface
Data bus diagnostic interface functions
Renewing data bus diagnostic interface
2.4
AG. Volkswagen AG d convenience

Removing
agen and installing
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central
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ility
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an
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t
or control
2.4.1auGeneral
description - convenience system central
ac
s
unit , spage
389
2.4.2 Removing and installing convenience system central

control unit , page 390
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
2.4.3 Renewing convenience system central control unit ,

page 391
2.4.4 Adapting convenience system central control unit , page

391
2.4.1
General description - convenience sys

tem central control unit
Note
If the convenience system central control unit - J393- is to be
ht
rig
py
Co
t.
do
c
um
en
renewed, the procedure

carried out first.
Prote
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agen
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tions
AG.
The convenience system control unit - J393- is responsible for the
following in the vehicle:
Sliding/tilting sunroof control (release instruction)
Power window control (release instruction)
Central locking control
Anti-theft alarm control
Radio-wave receiver
Rear lid lock
2. Control units
389

Convenience operation
Some of the above mentioned functions can be adapted
page 391 .
The convenience system central control unit - J393- is equipped
with self-diagnosis, which makes fault finding easier.
ing mode page 403 .
2.4.2
Removing and installing convenience

system central control unit
Note
AG. Volkswagen AG d
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rrectness of i
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a
t
i
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wit
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le
Removing:
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
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If the convenience system central control unit - J393- is to be re

newed, the procedure
page 391 for reading the codes stored in the unit must be carried
out first.
key.
AG.
Rep. gr.97 - Wiring
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390
ht
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Release connectors -A- and pull them off convenience system

central control unit - J393- .
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Release wiring harness -arrow- from retainer.

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ce
un
le
Release clip -A- and push control unit upwards in

Using a screwdriver, carefully unclip central convenience sys

tem control unit - J393- from bracket in -direction of arrow-.
Installing:
AG.
agen
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by
Prote
cted
by c
o
p
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gh
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op
yi

ht
rig
py
Co
t.
Renewing convenience system central

control unit
do
c
um
en
2.4.3
r
te o
iva
r
rp
fo
g
n

Body
Convenience system
J393 - Renewing convenience system central control unit
2.4.4
Adapting convenience system central

control unit
The following functions can be adapted:

Activating and deactivating single door opening
Activating and deactivating automatic locking at >15 km/h
Activating and deactivating automatic unlocking when ignition
key is removed
Activating and deactivating country settings for intelligent
alarm horn
Activating and deactivating battery monitoring system (soun
der)
2. Control units
391

. Volkswage
delay when driver's door is opened
ility
ab
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pe
rm
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d
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AG
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not
l
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Activating and deactivating
convenience
actuation
viaguradio
b
ara
d
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ise
remote control unit
r
o
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h
t
u
ra
a
c
s
Activating and
deactivating
anti-theft
alarm
system
alarm
s
Sensitivity of tilt angle sensor

es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Note

Body

c
o
p
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C
op
yi
agen
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Vo
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Convenience system
ht
rig
py
Co
t.

Prote
cted
by

AG.
J393 - Adapting convenience system central control unit
2.5
Removing and installing special vehicle

control unit
2.5.1 General description - special vehicle control unit , page

392
2.5.2 Removing and installing special vehicle control unit ,
page 393
2.5.3 Coding special vehicle control unit , page 394
2.5.4 Connector pin assignment - Special vehicle control unit
(MFG 1), page 394
2.5.5 Connector pin assignment - Special vehicle control unit
(MFG 2), page 398
2.5.1
General description - special vehicle

control unit
Note
tions
The special vehicle control unit - J608- is used by the following
special-purpose vehicles, their special equipment and functions:
392
Rep. gr.97 - Wiring
do
c
um
en
r
te o
iva
r
rp
fo
g
n

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Sensitivity of interior monitoring system

Taxis
Driving schools
Disabled
The special-purpose vehicle control unit - J608- is equipped with

self-diagnosis, which makes fault finding easier.
ing mode page 403 .
2.5.2
Note
Removing and installing special vehicle

control unit
Prote
cted
by
Undo and remove the 2 nuts -2-.
AG.
Remove footwell cover on driver side -1- General body re

pairs, interior; Rep. gr. 68 ; Compartments, covers and trims;
Removing and installing footwell trims .
agen
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.
C
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yi
ht
rig
py
Co
t.
Removing:
r
fo
ng
The special vehicle control unit is located on the airbag control

unit, in the area of the centre tunnel, under the dash panel.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
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d
p
Special protection vehicles
ility
ab
y li
an
pt
ce
Special signal vehicles
un
le
Driving schools for the disabled
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tee
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or
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ac
a
ss
Note
Two sorts of nuts are used: plastic nuts (1.5 Nm) and metal nuts
(3.5 Nm).
Pull retaining bracket -3- downwards off threaded bolts.
4 - Special vehicle control unit
2. Control units
393

ility
ab
y li
an
pt
ce
Unscrew securing bolts on control unit -arrows-.

For reasons of clarity, the dash panel is not shown in the illustra
tion.
Take special vehicle control unit downwards and out of airbag
control unit.
Installing:
Prote
cted
by
AG.
Coding special vehicle control unit

agen
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Vo
by
c
o
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C
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2.5.3
ht
rig
py
Co
t.
r
fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
Release and disconnect connector -arrow-
AG. Volkswagen AG d
agen
oes
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not
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V unit.
gu
y
from control
b
ara
d
nte
ise
r
o
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t
u
ra
a
c
s
s

Body
Electrical system
Multifunction control unit
Multifunction control unit functions
Coding the multifunction control unit
2.5.4
Connector pin assignment - Special vehicle control unit (MFG 1)
Contact Designation Output/in

put
Functioning
Earth connec
tion
Earth connec
tion
Earth connec
tion
High side: 6 A
2
3
4
394
Terminal
31, earth
Terminal
31, earth
Terminal
31, earth
A01
Input
Input
Input
Output
Rep. gr.97 - Wiring
Taxis
Authorities
Driving schools Driving aid
Supply Supply for

for radi radio tele
oteleph phone 1
ony
Not assigned
Not as
signed

put
Functioning
High side: 6 A
A02
10
11
r
fo
ng
12
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
A12
Output
High side:
0.4 A
A13
Output
Low side 0.2 A
15
A14
Output
16
A15
Output
High side:
0.4 A
Low side 0.2 A
17
A16
Output
Low side 0.2 A
18
A17
Output
Low side 0.2 A
AG.
14
Supply for
radio tele
phone 2
Not assigned
Not as
signed
Terminal 15 Terminal 15
Terminal 15
Not as
signed
Not assigned
Not as
signed
Not assigned
Not as
signed
Isolation re Not assigned

lay for 2nd
battery
Isolation re Not assigned
lay for 2nd
battery
X
X
Not as
signed
Not as
signed
Activation Not assigned

via button
for engine
run-on, ter
minal 15
Not as Special sig Not assigned
signed nal siren ac
tivated
Warning Warning
Not assigned
light for light for en
roof
gine run-on
symbol button
button
Not as Not as
Supply for
signed signed
warning buzzer
Not as Urban/
Warning light
signed country
for warning
changebuzzer button
over of sig
nal installa
tion
Warning Warning
Warning light
light for light for ra for footwell light
interior dio tele
button
lighting phone but
button
ton
Speed Speed sig Speed signal
signal
nal
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13
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Authorities
ility
ab
y li
an
pt
ce
un
le
Supply
for radio
frequen
cy data
trans
mission
A03
Output
High side: 5 A Termi
nal 15
. Volkswagen AG
G
A
n
e
g
does
swa
k
n
l
o
o
A08_1 by V Output
Pot. fr. relay t guHandd
ran
contact 0.5 A afree
ise
tee
r
o
h
function
t
or
u
a
of two-ac
ss
way ra
dio
A08_2
Output
Pot. fr. relay
Handcontact 0.5 A free
function
of twoway ra
dio
A09_1
Output
Pot. fr. relay
Radio
contact 0.5 A distress
signal
A09_2
Output
Pot. fr. relay
Radio
contact 0.5 A distress
signal
A10
Output
High side:
X
0.4 A
A11
Output
High side:
Not as
0.4 A
signed
ht
rig
py
Co
t.
Output
Taxis
Not as
signed
X
Activation
via button
for engine
start, termi
nal 50
Not as
signed
Door con
tact switch
status on
driver side
Not as
signed
Not as
signed
Warning
light for re
mote con
trol button
Speed sig
nal
19
20
21
2. Control units
395

22
A04
Output
High / low side Supply 1 Rear flash Not assigned

3A
for roof ing lights
symbol
23
A05
Output
24
A06
Output
25
A07
Output
26
Terminal
30, positive
Terminal
30, positive
Terminal
30, positive
Terminal
31, nega
tive
Terminal
31, nega
tive
Terminal
31, nega
tive
Input
High / low side Supply 2 Left addi

Not assigned
3A
for roof tional turn
symbol signal
High / low side Not as Right addi Not assigned
3A
signed
gen AGturn
AG. Volkswational
does
agen
signal
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High
Not
assigned
nte
is side, 1 A Not as Weapon
r
o
eo
cur signed box activa
th
upermanent
ra
a
c
s
tion
s rent, 6 A pulsed
current
Supply con
X
X
X
nection
Supply con
X
X
X
nection
Supply con
X
X
X
nection
Earth connec
X
X
X
tion
48
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Input
Earth connec
tion
r
te o
iva
r
rp
fo
g
n
Earth connec
tion
Not as
signed
Not as
signed
X
X
X
X
X
X
LIN_0
Earth
LIN bus
Earth output
X
X
X
X
X
X
X
X
LIN_1
Earth
Earth
CAN bus,
high
CAN bus,
low
LIN bus
Earth output
Earth output
CAN bus, con
venience, high
CAN bus, con
venience, low
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
49
50
51
52
396
Supply for
steering
wheel re
mote con
trol
Not as
signed
do
c
um
en
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
Input
AG.
31
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Vo
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30
Input
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
29
Input
Authorities
ht
rig
py
Co
t.
28
Input
Taxis
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
27
pe
rm
itte
d
un
le
Functioning
ility
ab
y li
an
pt
ce

put
Rep. gr.97 - Wiring

put
Functioning
Taxis
53
Supply con
nection
Supply con
nection
Supply con
nection
54
55
56
57
58
59
60
61
Terminal
Input
30, positive
Terminal
Input
30, positive
Terminal
Input
30, positive
Authorities
AG. Volkswagen AG d
agen
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V
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ise
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s
s
Relay 0.5 A
Not as
signed
Not as
signed
E01
Input
Low active
Engine run- Switch opera Not as

on button
tion, front pas signed
senger
E02
Input
Low active
E03
Input
Low active
E04
Input
Low active
E05
Input
Low active
68
E06
c
o
p
yri
gh
t.
C
op
yi
Passive
taxi
alarm
button
Passive
taxi
alarm
button
Off but
ton for
taxi
alarm
Button
for interi
or light
ing
Button
for taxi
roof sign
Input
Low active
69
E07
Input
Low active
70
E08
Input
Low active
Not as
signed
71
E09
Input
Low active
Not as
signed
Button for Not assigned

suppres
sion of inte
rior lighting
urban/
country
changeover
Not as
Not assigned
signed
72
E10
Input
Low active
Not as
signed
Not as
signed
Button
for
handfree
function
of twoway ra
dio
Not as
signed
Not as
signed
Starter in
hibitor
Not as
signed
Footwell light
button
Not as
signed
Warning buz
zer button
Not as
signed

two-way ra
dio supply
do
c
um
en
Prote
cted
by
67
AG.
66
agen
lksw
Vo
by
65
Not as
signed
ht
rig
py
Co
t.
64
Not assigned
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
62
63
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Output
ility
ab
y li
an
pt
ce
A08-norm.
closed
Not assigned
Not assigned
Not assigned
Button for
front left
window
opening
Button for
front left
window
closing
Button for
front right
window
opening
Button for
front right
window
closing
Engine start
button
Remote
control but
ton
Not as
signed
2. Control units
397
un
le
ility
ab
y li
an
pt
ce
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
Caddy 2004
ir se , Caddy 2011
tee
o
h
t
or
Electrical
u system - Edition 10.2014
ac
a
ss
Taxis
Authorities
73
Not as
signed
Radio
receiver
for taxi
alarm
Off sta
tus input
of taxi
meter
Not as
signed
Not as
signed
Not as
signed
Not assigned
Low active
74
E12
Input
High active
75
E13
Input
High active
76
E14
Input
High active
SDI BKGD
SDI VCC
SDI GND
SDI reset
Output
Output
Output
Output
SDI BKGD
SDI VCC
SDI GND
SDI reset
Prote
cted
by
AG.
r
te o
iva
r
rp
fo
g
n
c
o
p
yri
gh
t
.
C
op
yi
77
78
79
80
81
82
83
84
85
86
87
88
X
X
X
X
agen
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Vo
by
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Input
Not assigned
Not as
signed
Not as
signed
Off status
input, spe
cial signal
Not assigned
Not as
signed
Not as
signed
Not assigned
Not as
signed
X
X
X
X
do
c
um
en
E11
ht
rig
py
Co
t.
pe
rm
itte
d
Functioning
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

put
X
X
X
X
X
X
X
X
X
X
X
X
Pull-up
Earth
Watchdog- Output
disable
2.5.5
Earth
Watchdog-dis
able
X
X
X
X
Connector pin assignment - Special ve

hicle control unit (MFG 2)
Inputs:
Contact no.
Type
Taxi
Special vehicle
E 01
Low active
Passive taxi
alarm button
E 02
Low active
E 03
Low active
E 04
Low active
Active taxi alarm

button
Off button for taxi
alarm
Button for interior
lighting
E 05
Low active
Roof symbol but

ton
E 06
Low active
Button for unlock

ing rear doors
Engine run-on button Not assigned Switch for opera

tion of pedals by
front passenger
Button for two-way Not assigned Footwell light but
radio supply
ton
Starter inhibitor
Not assigned Warning buzzer
button
Button for interior
Button for
Button for front
lighting
front left win left window regu
dow regula lator, low
tor, low
Changeover be
Button for
Button for front
tween urban and
front left win left window regu
countryside
dow regula lator, high
tor, high
Button for switching Button for
Button for front
daylight running
front right
right window reg
lights off
window reg ulator, low
ulator, low
398
Rep. gr.97 - Wiring
Driving aid
Driving school
and extra

Contact no.
Type
Taxi
Special vehicle
Driving aid
Driving school
and extra
E 07
Low active
Not assigned
Button for blue light
Button for front

right window reg
ulator, high
E08
Low active
Not assigned
Button for
front right
window reg
ulator, high
Engine start
button
Remote con
trol button
Not assigned
E 16
High active
E 17
E 18
High active
High active
Not assigned
Radio receiver for
taxi alarm
Off status input of
taximeter
Not assigned
Not assigned
Type
Taxi
A 01
High / low
side
High / low
side
High side
High side
Supply 1 for roof

symbol
Supply 2 for roof
symbol
Terminal 15
Not assigned
Not assigned Not assigned
High side
A 06
High side
A 07
High side
A 08
High side
A 09_C
Relay
A 09_NO
Relay
A 09_NC
Relay
Supply for radio

telephone 1
Supply for radio
telephone 2
Terminal 15
Rear flashing
lights
Not assigned
Left additional turn
signal
Not assigned
Right additional
turn signal
Not assigned
Luggage compart
ment light
Supply output with Supply output with
protection against protection against
total discharge
total discharge
AG.
A 05
Special vehicle
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Vo
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Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
A 03
A 04
Not assigned
Status input from

special signalling
system
Not assigned
Not assigned
ht
rig
py
Co
t.
A 02
Not assigned
Not assigned
Not assigned
Outputs:
Contact no.
Not assigned
Engine start but

ton
Remote control
button
Button for left turn
signal
Button for right
turn signal
Button for main
beam
Button for dipped
beam
Horn plate
Not assigned
Test button
Not assigned
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Low active
High active
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
E 14
E 15
ility
ab
y li
an
pt
ce
Button for tonal se

quence standby
E 09
Low active
Not assigned
Button for special
signal
E 10
Low active
Not assigned
Button for Stop Po
AG. Volkswagen AG d
lice, front
n
e
g
a
oes
ksw
not
Vol active
g
E 11
Low
Not
assigned
y
ua Button for Stop Po
db
ran
lice,
ise
tee rear
r
ho
t
or
ac for Please
E 12 s au
Low active
Not assigned
Button
s
Follow, rear
E 13
Low active
Not assigned
Microphone button

Driving aid
Driving school and

extra
Not assigned
Not assigned
Not assigned
Not assigned
Terminal 15
Supply for remote
control
Not assigned
Terminal 15
Supply for remote
control
Supply for footwell
lights
Supply for warning
buzzer
Not assigned
Not assigned
Not assigned
Supply output
with protection
against total dis
charge
Not assigned
Radio distress sig Terminal 15 from

nal
ignition/starter
switch
Radio distress sig Not assigned
Not assigned
nal
Not assigned
Terminal 15 to on Not assigned
board supply con
trol unit
Supply output with

protection against
total discharge
Not assigned
Not assigned
Not assigned
2. Control units
399

Not assigned
or assigned
Not
ac
Not assigned
Not assigned
Terminal 50 for
engine start
Not assigned
Not assigned
Not assigned
Not assigned
Terminal 50 for en
gine start
Not assigned
High side
Not assigned
Not assigned
High side
Isolation relay for

2nd battery
Not assigned
Not assigned
High side
Not assigned
Indicator lamp for

dipped beam
Indicator light for
left turn signal
High side
Not assigned
High side
Door status
un
le
r
fo
ng
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
A 17
High side
Not assigned
Not assigned
Not assigned
Engine run-on, ter
minal 15
Activating se
quence of sounds
for signalling sys
tem
Isolation relay for
2nd battery
Indicator light for
blue light
Error indication,
special signalling
system
Indicator light for
status of special
signal
Door status
A 18
Low side
A 19
Low side
A 20
Low side
A 21
Low side
A 22
A 23
Low side
Low side
400
Rep. gr.97 - Wiring
Not assigned
Not assigned
Not assigned
Indicator light for

right turn signal
Main beam warn

ing lamp
Warning light for Warning light for Warning light for Warning light for
roof symbol button engine run-on but remote control
remote control but
ton
button
ton
Indicator light for Indicator light for Not assigned
Indicator light for
interior lighting
interior lighting
warning buzzer
button
button
button
Not assigned
Urban/countryside Not assigned
Warning light for
changeover for
footwell light but
signalling system
ton
Not assigned
Warning light for Not assigned
Not assigned
radio telephone
button
Speed signal
Speed signal
Speed signal
Speed signal
Not assigned
Indicator light for Door status
Door status
daylight driving
lights button
Prote
cted
by
A 16
Relay
Relay
High side
assigned
Not assigned
Not assigned
Not assigned
AG.
A 15
Driving school and

extra
ua
ran
tee
agen
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by
A 14
Driving aid
c
o
p
yri
gh
t.
C
op
yi
A 13
not
Special vehicle
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3.1 Repairing electrical wiring harnesses and plug-in connec

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3.1
Repairing electrical wiring harnesses

and plug-in connections
3.1.1 Wiring harness and connector repairs, page 401

3.1.2 Contact surface cleaning set VAS 6410 , page 401
3.1.1
Wiring harness and connector repairs
General information for wiring harness and connector repair is

Wiring harness and connector repair .
3.1.2
Contact surface cleaning set - VAS

6410-
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6410- is available in the workshop manual Electrical system,
Rep. gr. 97 ; Contact surface cleaning set VAS 6410 .
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Electrical system, General information; Rep. gr. 97 ; Renewing
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Vehicle diagnosis, testing and infor

mation systems
General information for vehicle diagnosis, testing and information

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5. Vehicle diagnosis, testing and information systems
403

K0050367120-Electrical System

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Service

Service Department. Technical Information

All rights reserved.

Caddy 2004 , Caddy 2011

90 - Gauges, instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caddy 2004 , Caddy 2011

94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Caddy 2004 , Caddy 2011

Caddy 2004 , Caddy 2011

96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

Lights and controls in the dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caddy 2004 , Caddy 2011

Removing and installing light for vanity mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caddy 2004 , Caddy 2011

Caddy 2004 , Caddy 2011

Starter, current supply, CCS

(VRL007279; Edition 10.2014)

General description - battery

Assembly overview - battery

1.2.1 Assembly overview - vehicles without battery monitor

1.2.2 Assembly overview - vehicles with battery monitor control

Assembly overview - vehicles without

Warning notices and safety regulations

All the instructions and information regarding this manual are

All the instructions and information regarding this manual are

Caddy 2004 , Caddy 2011

7 - Clamping plate securing nut

Assembly overview - vehicles with bat

Warning notices and safety regulations

All the instructions and information regarding this manual are

Rep. gr.27 - Starter, current supply, CCS

All the instructions and information regarding this manual are

4 - Securing nut for positive

3 - Positive wire battery termi

2 - Securing nut for earth wire

1 - Battery earth terminal with

Caddy 2004 , Caddy 2011

Disconnecting and reconnecting battery

Danger of injury! Comply with the warning notices and safety

Caddy 2004 , Caddy 2011

Disconnecting the battery earth strap (open circuit) provides a

safe working environment for repairs to the electrical system.

The battery positive wire need only be disconnected for re

moval of the battery.

Special tools and workshop equipment required

Open cover -1- of battery protective jacket.

Only for vehicles with battery protective jacket:

In new vehicles, the battery box has been discontinued. Heat in

Rep. gr.27 - Starter, current supply, CCS

Torque wrench - V.A.G 1331-

Caddy 2004 , Caddy 2011

Battery terminal clamps must be fitted only by hand without

Guided fault finding with vehicle diag

Caddy 2004 , Caddy 2011

Removing and installing battery

1.4.1 Removing and installing battery, vehicles with petrol en

Removing and installing battery, vehi

Replacing battery on vehicles with Start/Stop system:

Because of its higher deep-cycle resistance, only an absorbent

In vehicles with a battery sensor (start-stop system), the bat

tery has to be parameterised after a new starter battery has