VOLKSWAGEN GOLF VARIANT 2010 (14) PDF Document

Danger of injury! Observe warning notices and safety regulations mentioned on page 1.

All the instructions and information for this manual are found in the workshop manual „Electrical System, General Information“. A link to this workshop manual is not possible at present for technical reasons. Please select the workshop manual „Electrical System, General Information“ manually in ELSA.

The specified torque is 6 Nm.

The specified torque is 6 Nm.

The specified torque is 35 Nm.

Caution:

Always make sure that the electrical system of the vehicle is protected by disconnecting the battery -A- before any work on the electrical system starts.

Do not unfasten or remove the earthing cable from your body. Only remove the negative terminal (-) of the battery -A- .

The positive terminal (B+) of the battery -A- is only allowed to be removed if the battery -A- has been removed from the vehicle.

Observe warning notices and safety regulations mentioned on page 1.

Caution:

Switch off ignition and all electrical consumers.

Remove the ignition key.

Steps after connecting battery -A- Step Performed

A loosely fitted battery -A- creates the following dangers:

Shortened service life due to damage from vibration (danger of explosion)

The cells in the battery -A- will be damaged if the battery -A- is not secured correctly.

Damage to battery housing due to clamping plate (possibility of acid leaking, with high consequential costs)

Poor crash safety

The specified torque is 10 Nm.

The specified torque is 15 Nm.

The specified torques for the starter -B- bolts are:

Nut -3-: 15 Nm

Bolt -4-: M12 = 75 Nm

Bolt -4-: M10 = 40 Nm

Checking is mentioned on page 13.

The specified torque for the nut of the B+ wire on the rear of the alternator -C- is 15 Nm.

Always renew poly V-belt if it is defective. This will avoid possible breakdowns or operating problems.

Carry out following procedures:

Crank engine at vibration damper/belt pulley using a socket.

Check poly V-belt for:

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

The assembly overview for the Alternator -C- 1.4l petrol engine shows the following numbered items with specified torques:

Not illustrated:

Nut of B+ wire on rear of alternator: 15 Nm

Nut of wire holder on back of alternator: 3.2 Nm

Poly V-belt pulley without freewheel: 65 Nm

Poly V-belt pulley with freewheel: 80 Nm

Special tools and workshop equipment required are:

Torque wrench -V.A.G 1331-

Locking pin -T10060A-

When battery -A- is disconnected and reconnected, the procedure described in the workshop manual must be strictly observed on page 4.

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 destroyed!

The assembly overview for the Alternator -C- 1.6l petrol engine shows the following numbered items with specified torques:

Not illustrated:

Nut of B+ wire on rear of alternator: 15 Nm

Nut of wire holder on back of alternator: 3.2 Nm

Poly V-belt pulley without freewheel: 65 Nm

Poly V-belt pulley with freewheel: 80 Nm

Poly V-belt pulley without freewheel: 65 Nm

Poly V-belt pulley with freewheel: 80 Nm

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 destroyed!

The assembly overview for the Alternator -C- 2.0l FSI engine shows the following numbered items with specified torques:

Not illustrated:

Nut of B+ wire on rear of alternator: 15 Nm

Nut of wire holder on back of alternator: 3.2 Nm

Poly V-belt pulley without freewheel: 65 Nm

Poly V-belt pulley with freewheel: 80 Nm

Special tools and workshop equipment required are:

Torque wrench -V.A.G 1331-

Spring-type clip pliers -VAS 5024A-

Locking pin -T10060-

The assembly overview for the Alternator -C- 1.9l diesel engine shows the following numbered items with specified torques:

Not illustrated:

Nut of B+ wire on rear of alternator: 15 Nm

Nut of wire holder on back of alternator: 3.2 Nm

Poly V-belt pulley without freewheel: 65 Nm

Poly V-belt pulley with freewheel: 80 Nm

Special tools and workshop equipment required are:

Torque wrench -V.A.G 1331-

Locking pin -T10060A-

The assembly overview for the Alternator -C- 2.0l diesel engine shows the following numbered items with specified torques:

Not illustrated:

Nut of B+ wire on rear of alternator: 15 Nm

Nut of wire holder on back of alternator: 3.2 Nm

Poly V-belt pulley without freewheel: 65 Nm

Poly V-belt pulley with freewheel: 80 Nm

Special tools and workshop equipment required are:

Torque wrench -V.A.G 1331-

Locking pin -T10060-

The assembly overview for the Alternator -C- 2.0l TSI engine shows the following numbered items with specified torques:

Not illustrated:

Nut of B+ wire on rear of alternator: 15 Nm

Nut of wire holder on back of alternator: 3.2 Nm

Poly V-belt pulley without freewheel: 65 Nm

Poly V-belt pulley with freewheel: 80 Nm

Special tools and workshop equipment required are:

Torque wrench -V.A.G 1331-

Torque wrench -V.A.G 1332-

Spring-type clip pliers -VAS 5024A-

When battery -A- is disconnected and reconnected, the procedure described in the workshop manual must be strictly observed on page 4.

The procedure for removing and installing the voltage regulator -C1- is on page 168.

The assembly overview for the alternator -C- has the following cross-references:

Removing and installing: page 132

Checking: page 89

Securing battery positive wire: page 88

Removing and installing poly V-belt pulley: page 163

The poly V-belt has the following cross-references:

Checking: page 88

Removing and installing: Engine; Rep. gr. 13

Process: power unit; Rep. gr. 13

Tighten threaded connections to specified torques on page 90.

The specified torque for the nut of wire holder on back of alternator is 3.2 Nm.

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 steering requests the driver to continue passing by the parking space until the vehicle is in a position from which rapid parking is possible. When reverse gear is engaged, the park assist steering undertakes lateral guidance of the vehicle by actuating the EPS (electronic power steering) and steers the vehicle into the parking space in one movement along a calculated, nominal path. The driver maintains operation of the pedals (accelerator, clutch, brake) and longitudinal vehicle guidance, and therefore determines the parking speed. During the parking process, the park assist steering sensors are used together with the parking aid senders to monitor proximity.

The following conditions lead to abortion of the parking process with park assist steering:

The park assist steering system is switched off via the park assist steering button -E581- .

Ignition is switched off

Parking speed too high (greater than 7 km/h)

Steering intervention by driver during parking process

Disengagement of reverse gear

Vehicle standstill time limit exceeded (approx. 30 seconds)

ESP switched off or ESP intervention

TCS intervention

Trailer on the vehicle

Front parking aid is switched on.

Sensors detect a status which endangers secure determination of the vehicle position.

System malfunction

WARNING:

Responsibility during parking is borne by the driver.

The park assist steering system cannot replace the driver’s attentiveness.

The sensors have blind spots, in which persons and objects can not be registered.

Pay particular attention to small children and animals, as these are not always detected by the sensors.

The 4-channel parking aid assembly overview shows the following components:

The 8-channel parking aid assembly overview shows the following components:

The reversing camera system supports the driver during reversing by providing the driver with an image of the traffic situation behind the vehicle on the radio/navigation system display. The system is available as an option. The system is activated when reverse gear is engaged, even if the radio/navigation system is switched off. The reversing camera system consists of the following components:

Reversing camera -R189-

Control unit with display unit for radio and navigation -J503-

Steering wheel with steering angle sender -G85-

Extensive preliminary work is required before actual calibration can be carried out using vehicle diagnosis, testing and information system -VAS 5051B- . This is described in the following.

Calibrate reversing camera system page 378.

To carry out calibration, vehicle must be positioned on a firm, level surface. It is not permissible for anybody to be inside vehicle during measurement. Vehicle must not be moved during measurement, and opening and closing vehicle doors is prohibited.

Connect vehicle diagnosis, testing and information system -VAS 5051B- .

Set steering wheel sender -G85- to 0 position (wheels straight ahead).

Overview of measuring setup:

Wheel centre mounting -VAS 6350/1-

Wheel centre mounting -VAS 6350/1-

Right bracket (Spacing laser -VAS 6350/2- mounting)

Linear laser -VAS 6350/3- (Switching on and off Owner’s manual)

Plastic foot (Three on underbody, Adjustable for setting the horizontal position)

Spacing laser -VAS 6350/2- (Notes on operation Owner’s manual)

Spirit level on calibration unit (For checking horizontal position)

Left bracket (Spacing laser -VAS 6350/2- mounting)

Calibration unit -VAS 6350/4- (Distance between angle of calibration unit -VAS 6350/4- and wheel centre mounting -VAS 6350/1- : 1.20 m to 1.70 m -dimension A)

Assembling, setting-up calibration unit -VAS 6350/4-:

Secure three wheel bolt adapters in each hole circle of wheel centre mounting -VAS 6350/1- .

Position paddles on both wheel centre mountings -VAS 6350/1- and secure with clamping bolts.

Insert wheel centre mountings -VAS 6350/1- into wheel bolts of rear wheels. Wheel centre mountings -VAS 6350/1- are positioned and secured in the adapters by the O-rings.

Use clamp nuts to adjust paddles so that they move freely just above the floor. Make sure the paddles can move freely.

Position the calibration device -VAS 6350/4- behind vehicle at a distance of 1.20 m to 1.70 m to the angle brackets of the calibration device -VAS 6350/4- and the paddles on the wheel centre mountings -VAS 6350/1- , see -dimension A- Item 9).

Position the calibration device -VAS 6350/4- horizontally. Do this by turning the plastic feet under the calibration unit -VAS 6350/4- until the air bubble in the spirit level is precisely in the centre of the indicator -arrow-.

Switch on the linear laser -VAS 6350/3- on calibration unit -VAS 6350/4- -1- and align the entire calibration unit -VAS 6350/4- so that the laser beam -2- hits the rear end of the vehicle centrally above the VW logo.

Switch on the spacing laser -VAS 6350/2- with the ON button. The following display appears and the laser is activated: (Display shows distance in metres).

The onboard supply control unit -J519- and the relay carrier attached to the onboard supply control unit -J519- located on left of dash panel form one unit and cannot be separated (up to MY2009).

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 malfunction!

Keep to the specified sequence when removing components.

When battery -A- is disconnected and reconnected, the procedure described in the workshop manual must be strictly observed on page 4.

When removing and installing components that are in view (switches, covers, trim), mask off areas where tools (removal wedge -VAS 3409- , screwdriver) are used to lever out those components using commercially available masking tape.

Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evaporate when the bulb is switched on and cause the glass envelope to cloud over.

When installing cover cap, ensure that it seats properly. The ingress of water will lead to permanent damage to the headlight.

When installing cover cap, ensure that it seats properly. The ingress of water will lead to permanent damage to the headlight.

Do not touch glass envelope when fitting bulb. Fingers leave traces of grease on the glass envelope, which evaporate when the bulb is switched on and cause the glass envelope to cloud over.

When installing cover cap, ensure that it seats properly. The ingress of water will lead to permanent damage to the headlight.

Adjust headlight settings and adjust headlights if necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

Procedure:

Turn light switch to position “0”.

Clean headlight lens.

Left headlight:

Remove protective film on back of assembly film -D- in area -C- only.

Align positioning film -D- with the bottom edge to line -B- on the lens of the headlight.

Align positioning film -D- at the same time with its radius to line -A- on the lens of the headlight.

Push down in area -C- on the headlight lens.

Carefully pull application film -D- off the lens of the headlight again.

The masking film -C- remains on the headlight lens.

Right headlight:

Remove protective film on back of assembly film -D- in area -C- only.

Align positioning film -D- with the bottom edge to line -B- on the lens of the headlight.

Align positioning film -D- at the same time with its radius to line -A- on the lens of the headlight.

Push down in area -C- on the headlight lens.

Carefully pull application film -D- off the lens of the headlight again.

The masking film -C- remains on the headlight lens.

Customers should be informed of how to remove residual adhesive after detaching the masking section.

WARNING:

Within the glass envelope of a gas discharge bulb, pressure can range from between 7 bar (cold) and 100 bar (hot). Temperatures can reach up to 700 degrees Celsius on the glass bulb. The reflector is therefore hot as well.

There is a risk of injury from burning.

Always wear safety goggles and gloves when removing and installing gas discharge bulbs!

Procedure:

Connect vehicle diagnosis, testing and information system -VAS 5051B- .

In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

Using GoTo button, select „Functions/component“ and the following menu options in succession:

Body

Electrical system

01 – On Board Diagnosis capable systems

Automatic headlight range control

Automatic headlight range control functions

Coding automatic headlight range control

Once the control unit for headlight range control -J431- has been coded, a headlight basic setting must be carried out ⇒ Maintenance ; Booklet 20.1 ; Descriptions of work .

Procedure:

Connect vehicle diagnosis, testing and information system -VAS 5051B- .

In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

Using GoTo button, select „Functions/component“ and the following menu options in succession:

Body

General body repairs

Parking aid

Parking aid functions

Parking aid final control diagnosis

To check parking aid system as a whole, perform final control diagnosis page 354.

Procedure:

Connect vehicle diagnosis, testing and information system -VAS 5051B- .

In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

Using GoTo button, select „Functions/component“ and the following menu options in succession:

Body

General body repairs

Parking aid

Electrical components of parking aid

Procedure:

Connect vehicle diagnosis, testing and information system -VAS 5051B- .

In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

Using GoTo button, select „Functions/component“ and the following menu options in succession:

Body

General body repairs

Park assist steering

Park assist steering functions

Park assist steering button

Procedure:

Connect vehicle diagnosis, testing and information system -VAS 5051B- .

In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

Using GoTo button, select „Functions/component“ and the following menu options in succession:

Body

Electrical system

01 – On Board Diagnosis capable systems

Onboard supply control unit

Functions

Check remote control unit key

Procedure:

Connect vehicle diagnosis, testing and information system -VAS 5051B- .

In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

Using GoTo button, select „Functions/component“ and the following menu options in succession:

Body

Electrical system

01 – On Board Diagnosis capable systems

Onboard supply control unit

Functions

Code rain/light sensor

Procedure:

Connect vehicle diagnosis, testing and information system -VAS 5051B- .

In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

Using GoTo button, select „Functions/component“ and the following menu options in succession:

Body

Electrical system

01 – On Board Diagnosis capable systems

Onboard supply control unit

Functions

Adapt sensitivity of interior monitoring

Procedure:

Connect vehicle diagnosis, testing and information system -VAS 5051B- .

In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

Using GoTo button, select „Functions/component“ and the following menu options in succession:

Body

Electrical system

01 – On Board Diagnosis capable systems

Onboard supply control unit

Functions

Adapting footwell light dimmer value

Procedure:

Connect vehicle diagnosis, testing and information system -VAS 5051B- .

In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

Using GoTo button, select „Functions/component“ and the following menu options in succession:

Body

Electrical system

01 – On Board Diagnosis capable systems

Onboard supply control unit

Functions

Adapt convenience operation via remote control

Procedure:

Connect vehicle diagnosis, testing and information system -VAS 5051B- .

In vehicle diagnosis, testing and information system -VAS 5051B- , select „Guided fault finding“.

Using GoTo button, select „Functions/component“ and the following menu options in succession:

Body

Electrical system

01 – On Board Diagnosis capable systems

Onboard supply control unit

Functions

Visual feedback when locking