Volkswagen up! 2017 Instruction manual

Workshop Manual
up! 2017 ➤
up! 2020 ➤
Electrical system
Edition 10.2019
Service
Service Department. Technical Information

List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
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
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.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2020 Volkswagen AG, Wolfsburg D4B80651A52

Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when using testing and measuring instruments during a road test . . . . 1
2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Battery - general notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Types of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
27 - Starter, current supply, CCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Assembly overview - battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Removing and installing battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Disconnecting and connecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Removing and installing battery tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6 Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.7 Removing and installing earth wire with battery monitor control unit J367 . . . . . . . . . . . . 11
1.8 Adapting battery monitor control unit J367 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Assembly overview - alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Removing and installing alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Checking alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4 Removing and installing poly V-belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5 Removing and installing voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3 Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1 Assembly overview – starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2 Removing and installing starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4 Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5 Start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.1 General description - start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.2 Removing and installing voltage stabiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
90 - Gauges, instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1 Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.1 Assembly overview - dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.2 Removing and installing dash panel insert KX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.1 Assembly overview - horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.2 Removing and installing treble horn H2 and bass horn H7 . . . . . . . . . . . . . . . . . . . . . . . . 43
92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1 Windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.1 Assembly overview - windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.2 Moving wipers to service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.3 Removing and installing wiper blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.4 Removing and installing wiper arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.5 Adjusting wiper arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.6 Removing and installing wiper motor V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.7 Renewing wiper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
up! 2017 ➤ , up! 2020 ➤
Electrical system - Edition 10.2019
Contents i

1.8 Deactivating APP function of wiper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.9 Removing and installing rain and light sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2 Windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.1 Assembly overview - windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.2 Removing and installing washer fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.3 Removing and installing windscreen washer pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.4 Removing and installing washer jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.5 Adjusting spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3 Rear window wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.1 Assembly overview - rear window wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.2 Removing and installing wiper blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.3 Removing and installing wiper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.4 Adjusting wiper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.5 Removing and installing rear window wiper motor V12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4 Rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.1 Assembly overview - rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.2 Removing and installing spray jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.3 Adjusting spray jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5 Washer fluid lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.1 Repairing washer fluid lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1 Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.1 Assembly overview - headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.2 Removing and installing headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.3 Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.4 Adjusting headlight installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.5 Removing and installing front turn signal bulb M5 / M7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.6 Installing repair kit for headlight housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.7 Converting headlights from driving on right to driving on left . . . . . . . . . . . . . . . . . . . . . . . . 79
1.8 Converting headlights from driving on left to driving on right . . . . . . . . . . . . . . . . . . . . . . . . 79
1.9 Removing and installing headlight range control motor V48 / V49 . . . . . . . . . . . . . . . . . . 79
1.10 Removing and installing dipped beam bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.11 Removing and installing LED modules for daytime running light and side light L176 / L177
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.12 Removing and installing control unit for daytime running light and side light J860 / J861
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2 Fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.1 Assembly overview - fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.2 Removing and installing fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.3 Removing and installing fog light bulb L22 / L23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.4 Adjusting fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3 Lights in exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.1 Removing and installing turn signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.2 Removing and installing turn signal repeater bulb L131 / L132 . . . . . . . . . . . . . . . . . . . . 87
4 Tail lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.1 Assembly overview - tail lights in body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.2 Removing and installing bulb carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.3 Removing and installing tail light cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.4 Removing and installing tail light bulb M2 / M4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.5 Removing and installing rear fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.6 Removing and installing rear fog light bulb L46 / L47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.7 Removing and installing brake and tail light bulb M21 / M22 . . . . . . . . . . . . . . . . . . . . . . 92
4.8 Removing and installing reversing light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.9 Removing and installing turn signal bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
up! 2017 ➤ , up! 2020 ➤
Electrical system - Edition 10.2019
ii Contents

5 High-level brake light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.1 Assembly overview - high-level brake light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.2 Removing and installing high-level brake light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6 Number plate light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.1 Removing and installing number plate light X4 / X5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.2 Removing and installing bulb for number plate light X4 / X5 . . . . . . . . . . . . . . . . . . . . . . . . 97
7 Steering column switch module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
7.1 Assembly overview - steering column switch module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
7.2 Removing and installing steering column switch module . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.3 Removing and installing steering column electronics control unit J527 . . . . . . . . . . . . . . 101
7.4 Removing and installing base for steering column combination switch . . . . . . . . . . . . . . . . 103
7.5 Removing and installing turn signal switch E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.6 Removing and installing cruise control system switch E45 . . . . . . . . . . . . . . . . . . . . . . . . 103
7.7 Removing and installing intermittent wiper switch E22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.8 Removing and installing ignition/starter switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.9 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7.10 Removing and installing steering lock housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
7.11 Removing and installing ignition key withdrawal lock solenoid N376 . . . . . . . . . . . . . . . . 108
8 Parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
8.1 Assembly overview – parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
8.2 Removing and installing parking aid control unit J446 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
8.3 Removing and installing rear parking aid warning buzzer H15 . . . . . . . . . . . . . . . . . . . . . . 110
8.4 Removing and installing rear parking aid senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
9 Emergency braking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9.1 Removing and installing City Emergency Braking System . . . . . . . . . . . . . . . . . . . . . . . . . . 113
96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1 Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.1 Removing and installing Central locking SAFELOCK function warning lamp K133 . . . . . . 115
1.2 Renewing front interior light bulb W1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.3 Removing and installing bulb for front reading light W13 / W19 . . . . . . . . . . . . . . . . . . . . 117
2 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.1 Removing and installing rotary light switch EX1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.2 Removing and installing headlight range control regulator E102 . . . . . . . . . . . . . . . . . . . . 120
2.3 Removing and installing switch module in middle of dash panel . . . . . . . . . . . . . . . . . . . . 120
2.4 Removing and installing Start/Stop operation button E693 . . . . . . . . . . . . . . . . . . . . . . . . 122
2.5 Removing and installing hazard warning light button E229 . . . . . . . . . . . . . . . . . . . . . . . . 122
2.6 Removing and installing heated rear window button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2.7 Removing and installing button for driver assist systems E617 . . . . . . . . . . . . . . . . . . . . 122
2.8 Removing and installing buttons for seat heating E653 / E654 . . . . . . . . . . . . . . . . . . . . . . 123
2.9 Removing and installing mirror adjustment switch E43 / E168 . . . . . . . . . . . . . . . . . . . . . . 123
2.10 Removing and installing operating unit for window regulator in driver door E512 . . . . . . . . 123
2.11 Removing and installing front window regulator switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.12 Removing and installing driver side interior locking button for central locking system E308
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.13 Removing and installing centre console switch module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.14 Removing and installing button for emergency braking function . . . . . . . . . . . . . . . . . . . . 127
2.15 Removing and installing sliding sunroof adjustment regulator . . . . . . . . . . . . . . . . . . . . . . 128
2.16 Removing and installing front interior light/reading light . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.17 Removing and installing front passenger airbag deactivated warning lamp K145 . . . . . . 132
3 Immobiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3.1 Removing and installing immobiliser control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3.2 Removing and installing immobiliser reader coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4 Front camera for assist systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4.1 Assembly overview - front camera for assist systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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Contents iii

4.2 Removing and installing front camera for driver assist systems R242 . . . . . . . . . . . . . . . . 134
4.3 Calibrating front camera for driver assist systems R242 . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5 Cigarette lighter, socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.1 Removing and installing cigarette lighter U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.2 Removing and installing electric socket U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.3 Removing and installing bulb for illuminating cigarette lighter . . . . . . . . . . . . . . . . . . . . . . 143
97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1 Relay carriers, fuse holders, electronics boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.1 Removing and installing electronics box (E-box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.2 Removing and installing relay and fuse holder in electronics box . . . . . . . . . . . . . . . . . . . . 146
1.3 Removing and installing relay and fuse holder behind dash panel on driver side . . . . . . . . 148
2 Control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.1 Removing and installing onboard supply control unit J519 . . . . . . . . . . . . . . . . . . . . . . . . 154
2.2 Removing and installing data bus diagnostic interface J533 . . . . . . . . . . . . . . . . . . . . . . . . 155
3 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
3.1 Repairing electrical wiring harnesses and plug-in connections . . . . . . . . . . . . . . . . . . . . . . 156
4 Releasing and dismantling connector housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5 Repairing aerial wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
6 Vehicle diagnosis, testing and information systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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iv Contents

00 – Technical data
1 Safety information
(VRL013432; Edition 10.2019)
⇒ “1.1 Safety measures when working on vehicles with a start/
stop system”, page 1
⇒ “1.2 Safety precautions when using testing and measuring in‐
struments during a road test”, page 1
1.1 Safety measures when working on ve‐
hicles with a start/stop system
Observe the following when working on vehicles with a start/stop
system:
Risk of injury from unexpected engine/motor start
If the vehicle’s start/stop system is activated, the engine can start
unexpectedly. A message in the dash panel insert indicates
whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.
1.2 Safety precautions when using testing
and measuring instruments during a
road test
Observe the following if test and measuring equipment is required
during a road test:
WARNING
Risk of accident from distraction in road traffic.
– Have the test instruments and measuring equipment oper‐
ated by a second person.
CAUTION
Risk of injury from unsecured objects in vehicle.
– Secure test instruments and measuring equipment with a
suitable belt when vehicle is in motion.
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1. Safety information 1

2 Repair instructions
⇒ “2.1 Contact corrosion”, page 2
⇒ “2.2 Routing and attachment of lines”, page 2
2.1 Contact corrosion
Contact corrosion can occur when unsuitable fasteners (bolts,
nuts, washers, etc.) are used.
For this reason, only fasteners with a special surface coating are
used.
In addition, rubber, plastic and adhesives are made of non-con‐
ductive materials.
If there is any doubt about the suitability of parts, a general rule
is to use new parts ⇒ Electronic parts catalogue .
Please note:
♦ Only use genuine replacement parts which are tested and
compatible with aluminium.
♦ Only use Volkswagen Genuine Accessories.
♦ Damage resulting from contact corrosion is not covered by the
warranty.
2.2 Routing and attachment of lines
♦ Mark lines prior to removal to prevent them from being inter‐
changed and to ensure that they are fitted in their original
positions. This applies for fuel, hydraulic and vacuum lines as
well as lines for activated charcoal filter system and electrical
wiring. Where necessary, make sketches or take photographs.
♦ To avoid damage to lines, ensure adequate clearance from all
moving or hot components in the engine compartment on ac‐
count of the confined space.
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2 Rep. gr.00 - Technical data

3 Battery
⇒ “3.1 Battery - general notes”, page 3
⇒ “3.2 Types of battery”, page 3
3.1 Battery - general notes
All instructions and notes regarding this chapter are available un‐
der ⇒ Electrical system, General information; Rep. gr. 27 ;
Battery
3.2 Types of battery
All instructions and notes regarding this chapter are available un‐
der ⇒ Electrical system, General information; Rep. gr. 27 ;
Battery; Battery types
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3. Battery 3

27 – Starter, current supply, CCS
1 Battery
⇒ “1.1 Assembly overview - battery”, page 4
⇒ “1.2 Removing and installing battery”, page 6
⇒ “1.3 Disconnecting and connecting battery”, page 7
⇒ “1.4 Removing and installing battery tray”, page 9
⇒ “1.5 Checking battery”, page 10
⇒ “1.6 Charging battery”, page 10
⇒ “1.7 Removing and installing earth wire with battery monitor
control unit J367 ”, page 11
⇒ “1.8 Adapting battery monitor control unit J367 ”, page 11
1.1 Assembly overview - battery
Warning notices and safety regulations
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 tech‐
nical reasons. Please select the workshop manual “Electrical
System, General Information” manually in ELSA.
Battery load test
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 tech‐
nical reasons. Please select the workshop manual “Electrical
System, General Information” manually in ELSA.
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4 Rep. gr.27 - Starter, current supply, CCS

1 - Earth wire battery terminal
clamp
❑ Comply with the instruc‐
tions regarding threa‐
ded connections of the
battery terminals
⇒ page 4
❑ Depending on vehicle
equipment, the battery
monitor control unit -
J367- may be installed
instead.
❑ Removing and installing
battery monitor control
unit - J367-
⇒ page 11
❑ Specified torque for nut
securing wire to body:
20 Nm
2 - Securing nut for earth wire
battery terminal clamp
❑ Specified torque: 6 Nm
3 - Earth wire cover
4 - electronics box with holder
❑ Removing and installing
⇒ page 144
❑ Specified torque for nut
securing electronics box
to battery terminal
clamp for positive cable:
6 Nm
5 - Positive wire battery termi‐
nal clamp
❑ Specified torque for nut
securing electronics box
to battery terminal clamp for positive cable: 6 Nm
6 - Securing nut for positive wire battery terminal clamp
❑ Comply with the instructions regarding threaded connections of the battery terminals ⇒ page 4
❑ Specified torque: 6 Nm
7 - Clamping plate securing nut
❑ Specified torque: 9 Nm
8 - Clamping plate
❑ Observe assembly note
9 - Battery
❑ In the case of vehicles with start/stop system, observe instructions for replacement of battery
⇒ page 6 .
❑ Removing and installing ⇒ page 6
10 - Nuts for securing battery tray
❑ Specified torque: 9 Nm
11 - Battery tray
❑ Removing and installing ⇒ page 9
❑ Nuts for securing battery tray to body: 15 Nm
❑ Bolts for securing bracket of engine control unit to battery tray: 8 Nm
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1. Battery 5

1.2 Removing and installing battery
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
♦ Torque wrench - V.A.G 1783-
Note
Observe the warning notices and safety regulations ⇒ page 4
when disconnecting and connecting the battery.
Replacing battery on vehicles with start/stop system:
Because of its higher deep-cycle resistance, only a special starter
battery is used in vehicles with a start/stop system.
When renewing the starter battery, note correct part designation
in ⇒ ETKA (electronic parts catalogue) . Starter batteries for use
in vehicles with a start/stop system are marked with “AGM” (Ab‐
sorbent Glass Mat) or “EFB” (Enhanced Flooded Battery).
Note
♦ In vehicles with a battery sensor (start/stop system), the bat‐
tery has to be parametrised after a new starter battery has
been installed.
♦ The battery parametrisation sends the technical data of the
new battery to the battery monitor.
♦ Performing battery parametrisation ⇒ page 11 .
Removing
– Disconnect battery ⇒ page 7 .
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6 Rep. gr.27 - Starter, current supply, CCS

– Undo and remove bolt -1- and remove clamping plate -2-.
– Remove battery -4-.
Installing
CAUTION
Risk of explosion from poorly secured battery.
Shorter service life and acid leakage from vibration damage.
– Secure battery according to specification.
NOTICE
Risk of damage from poorly secured battery.
Damage to cells, battery housing and other components and
also poor crash safety.
– Secure battery according to specification.
Install in the reverse order of removal, observing the following:
– Place battery -4- on battery tray -3- and push towards rear.
– Put clamping plate -2- on and secure with bolt -1-.
– Check battery is firmly seated after installation.
– Connect battery ⇒ page 7 .
Note
If the battery is renewed, the battery monitor control unit - J367-
must be adapted ⇒ page 11 .
Specified torques
♦⇒ “1.1 Assembly overview - battery”, page 4
1.3 Disconnecting and connecting battery
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-
Recharging battery or jump start on vehicles with start/stop sys‐
tem:
When recharging or jump starting vehicles with start/stop system,
note the following: first connect charging cable to battery positive
terminal then body earth. This ensures that the battery sensor is
not bridged. The direct charging of the battery on the negative
terminal clamp means that the battery sensor is shunted and the
battery data are not registered by the sensor while charging. The
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1. Battery 7

values concerning the battery state saved in the data bus diag‐
nostic interface do not then correspond to the values of the
charged battery.
Note
Observe the warning notices and safety regulations when dis‐
connecting and connecting the battery.
Disconnecting battery
Note
♦ By disconnecting the battery earth wire (open circuit), safety
is ensured when carrying out work on the electrical system.
♦ The battery positive wire need only be disconnected for re‐
moval of the battery.
– Switch off ignition and all electrical consumers, and withdraw
ignition key.
– Fold up cover (if fitted) of earth wire on battery terminal clamp.
– First unscrew nut of earth wire battery terminal clamp and pull
terminal clamp off battery negative terminal -1-.
– Fold up cover of electronics box -1- and remove nut -2-.
– Release the catches -arrows- on each side of the electronics
box holder and remove electronics Box together with holder
upwards off the battery.
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8 Rep. gr.27 - Starter, current supply, CCS

– Then unscrew nut -1- of battery terminal clamp for positive
cable and pull terminal clamp -2- off battery positive terminal.
Connecting battery
Note
Comply with instructions regarding threaded connections of the
battery terminals ⇒ page 4 .
– Connect battery terminal clamp of positive cable -2- to positive
terminal of battery. Tighten securing nut -1- to specified torque
as per assembly overview ⇒ page 4 .
– Place electronics box together with holder onto battery and
secure with latches -arrows-.
– Screw on nut -2- and tighten to torque prescribed in assembly
overview ⇒ page 4 .
– Close cover -1- and secure with latch.
– Connect battery terminal clamp of earth wire to negative ter‐
minal -1- of battery.
– Tighten securing nut.
– Switch on ignition.
– Check time and adjust, if necessary.
– Completely open windows, and then completely close them.
– Then, with windows closed, pull window regulator switches
until relay can be heard to switch.
– Check convenience mode of the window regulators.
With convenience closing activated, windows must close fully
without the need for holding the window regulator switch.
Specified torques
♦⇒ “1.1 Assembly overview - battery”, page 4
1.4 Removing and installing battery tray
Special tools and workshop equipment required
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1. Battery 9

♦ Torque wrench - V.A.G 1331-
Removing
– Remove battery ⇒ page 6 .
– Unscrew securing nuts and bolts -2-.
– Loosen plastic nut (1.5 Nm) under wire retainer -4-, release
both fasteners -3- and pull off wire retainer -4- from battery
tray.
– Unclip all lines from refrigerant line retainer -5-.
– Pull catch -6- at bottom of refrigerant line retainer -5-, and pull
holder upwards off battery tray.
– Lift battery tray -1-.
– Disconnect connectors from engine control unit. To do this,
press catch -1- with a screwdriver in -direction of arrow-.
– Swing locking bar -2- in -direction of arrow-, and pull connector
-3- off engine control unit.
Installing
Install in the reverse order of removal, observing the following:
Specified torques
♦⇒ “1.1 Assembly overview - battery”, page 4
1.5 Checking battery
Check battery ⇒ Electrical system, General information; Rep. gr.
27 ; Checking battery .
With self-diagnosis, the battery - A- is monitored by the data bus
diagnostic interface - J533- in “Guided Fault Finding” mode ⇒ Ve‐
hicle diagnostic tester, Guided Fault Finding .
1.6 Charging battery
Charging battery ⇒ Electrical system, General information; Rep.
gr. 27 ; Charging battery .
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10 Rep. gr.27 - Starter, current supply, CCS

1.7 Removing and installing earth wire with
battery monitor control unit - J367-
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
Removing
– Separate electrical connector -2- on battery monitor control
unit - J367- -3-.
– Remove battery - A- ⇒ page 6 .
– Remove engine control unit ⇒ Rep. gr. 23 ; Engine control
unit; Removing and installing engine control unit - J623- .
– Unscrew nut -1-.
– Remove earth wire with battery monitor control unit - J367-
-2-.
Installing
Install in the reverse order of removal, observing the following:
– Adapt battery monitor control unit - J367- ⇒ page 11 .
Specified torques
♦⇒ “1.1 Assembly overview - battery”, page 4
1.8 Adapting battery monitor control unit -
J367-
After the installation of a new starter battery or a new battery
monitor control unit - J367- , the battery monitor control unit -
J367- must be adapted.
– Adapt battery monitor control unit - J367- ⇒ Vehicle diagnostic
tester.
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1. Battery 11

2 Alternator
⇒ “2.1 Assembly overview - alternator”, page 12
⇒ “2.2 Removing and installing alternator”, page 13
⇒ “2.3 Checking alternator”, page 16
⇒ “2.4 Removing and installing poly V-belt pulley”, page 16
⇒ “2.5 Removing and installing voltage regulator”, page 24
2.1 Assembly overview - alternator
1 - Alternator
❑ Removing and installing
alternator ⇒ page 13
❑ Checking alternator
⇒ page 16
❑ Removing and installing
poly V-belt pulley on al‐
ternator ⇒ page 16
❑ Removing and installing
voltage regulator
⇒ page 24
2 - Sliding bush
❑ Make sure that the slid‐
ing bushes slide freely
to obtain the specified
torque when securing
the alternator
3 - Electrical connector
4 - Cap
❑ For securing nut of bat‐
tery positive cable
5 - Nut for securing battery
positive cable
❑ 20 Nm
❑ Securing B+ cable on al‐
ternator
6 - Terminal 30/B+
7 - Sliding bush
❑ Make sure that the slid‐
ing bushes slide freely
to obtain the specified
torque when securing
the alternator
8 - Hexagon head flange bolt
❑ M8
❑ 23 Nm
9 - Hexagon head flange bolt
❑ M8
❑ 23 Nm
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12 Rep. gr.27 - Starter, current supply, CCS
Volkswagen Technical Site: https://vwts.ru

2.2 Removing and installing alternator
⇒ “2.2.1 Removing and installing alternator, petrol engine”, page
13
⇒ “2.2.2 Removing and installing alternator, natural gas engine”,
page 14
2.2.1 Removing and installing alternator, pet‐
rol engine
Note
Observe the warning notices and safety regulations when dis‐
connecting and connecting the battery.
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
Removing
– Disconnect battery ⇒ page 7 .
– Move lock carrier to service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier; Moving to and from service
position .
– Remove poly V-belt ⇒ Rep. gr. 13 ; Cylinder block, pulley end;
Removing and installing poly V-belt .
– Remove tensioner for poly V-belt ⇒ Rep. gr. 13 ; Cylinder
block (pulley end); Removing and installing tensioner for poly
V-belt .
Vehicles with air conditioning system
NOTICE
Risk of damage to air conditioner compressor, refrigerant lines
and hoses from kinking, stretching or bending.
– Do not stretch, kink or bend refrigerant lines and hoses.
– Remove air conditioner compressor from bracket ⇒ Heating,
air conditioning system; Rep. gr. 87 ; Air conditioner com‐
pressor; Removing air conditioner compressor from and in‐
stalling on bracket .
– Secure air conditioner compressor to lock carrier so that re‐
frigerant lines are not under tension.
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2. Alternator 13

Continued for all vehicles
– Unscrew 2 securing bolts -arrows- of alternator - C- .
– Detach alternator - C- -1- and turn it over, taking into account
the lengths of attached wires.
– Release and pull off DF cable connector -3-.
– Unscrew securing nut -2-, and detach positive cable -4- from
connection thread.
– Remove alternator - C- -item 1- downwards out of vehicle.
Installing
Install in the reverse order of removal observing the following:
Note
♦ When fitting used poly V-belts, take note of the direction of
rotation as marked during removal.
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐
nator, air conditioner compressor) are secure.
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
leys!
– Drive threaded bushes -A- approx. 4 mm in direction of arrow
out of housing of alternator - C- .
– Connect battery ⇒ page 7 .
– Start engine and check belt running.
Specified torques
♦⇒ “2.1 Assembly overview - alternator”, page 12
2.2.2 Removing and installing alternator, nat‐
ural gas engine
Note
Observe the warning notices and safety regulations when dis‐
connecting and connecting the battery.
Special tools and workshop equipment required
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14 Rep. gr.27 - Starter, current supply, CCS