Volkswagen Workshop Manuals

Volkswagen Workshop Manuals
Polo Mk4
Vehicle electrics > Electrical system > Starter-current supply-CC > Battery
Battery
WARNING
Risk of injuries! Observe safety warnings and instructions General information; Rep. gr.27.
Note
t
Check whether the vehicle has a coded radio. If so, request the anti-theft code before disconnecting the Battery A- earth wire.
Safe working conditions for repairing the electrical system are created by disconnecting the earth wire from the
Battery -A- (interrupting the current).
Upon reconnecting the Battery -A-, check the vehicle equipment (radio, clock, power locks and windows, etc.)
according to the Workshop Manual and/or instructions for use.
Special tools and workshop equipment required
t Torque Wrench - 4 to 20 Nm ( enc. 3/8") -VAG 1410-
"Torque wrench - 5 to 50 Nm (enc. 1/2")" -VAG

1331-
Vehicle electrics > Electrical system > Starter-current supply-CC > Battery
Vehicle electrics
>
Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect
Battery -A- - disconnect and connect
Note
The Battery -A- earth wire fastening should not be removed from the vehicle body.
WARNING
To avoid accident risks, always disconnect first the terminal connected to the negative pole of the Battery -A-.
Depending on the year and engine, the vehicle may be equipped with one of the fuse holders identified below:
Vehicles with fuse holder coupled to the Battery -Acover (version 1) Chapter.
Vehicles with fuse holder coupled to the Battery -Acover (version 2) Chapter.
Vehicles with fuse holder fastened to the Battery -Aconsole base (version 3) Chapter.
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect
Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect > Disconnect the BatteryA (Version 1).
Disconnect the Battery -A- (Version 1).
WARNING
Turn off the ignition and all electrical equipment, and remove the key from ignition.
Release the fuse holder -1- by pressing the lock -2- in

the direction of -arrow A-.
Move the fuse holder -1- in direction of -arrow B-, up
to the limit of the positive wire of the Battery -A-.
Loosen the securing nut -1- on the negative terminal

-2- and remove it from the Battery -A-.
Loosen the securing nut -3- on the positive terminal
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect > Connect the BatteryA (Version 1).
Connect the Battery -A- (Version 1).
Caution
Please observe the notes on the Battery -A-terminal fastening screw General information; Rep. gr.27.
Fasten the positive terminal -4- to the positive pole

of the Battery -A-.
Tighten the positive terminal screw -3- to the
specified tightening torque Chapter.
Fasten the negative terminal -2- to the negative pole

of the Battery -A-.
Tighten the negative terminal screw -1- to the
Lower the fuse holder -1- in the direction of - arrows

B-.
Lock the fuse holder -1- by pressing the lock -2- in
direction of -arrow A-.
WARNING
If the terminals are not firmly fastened to the Battery
-A-poles, the terminal connected to the negative pole
of the Battery -A-must be disconnected first, to avoid
risk of accidents.
Note
t The Battery -A- terminals should not be lubricated.
Connect the Battery -A- pole terminals manually and

without forcing, thus avoiding damages to the case.
Upon reconnecting the Battery -A-, check the vehicle

equipment (radio, clock, power locks and windows,
t
etc.) according to the Workshop Manual and/or
instructions for use.
Before carrying out measurements, check the
t external conditions and the connections of the
Battery -A-.
Vehicle electrics
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Vehicle electrics
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WARNING
Using the lever -arrow-, disconnect the fuse holder 2-, releasing it from the locks -1-.
Move the fuse holder cover -2- up.
Pull laterally the safety tabs -2- from the fuse holder
-1- in direction of the arrows, in order to release the
fuse holder from the tray -3- of the Battery -A-.
Move the fuse holder to the side up to the limit of

the positive wire of the Battery -A-.

Loosen the securing nut -3- on the positive terminal
Vehicle electrics
Vehicle electrics
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Caution

of the Battery -A-.

of the Battery -A-.
Insert the safety tabs in the housings -arrows- of the

Battery -A-tray.
Lowe the fuse holder -2- until it fits the locks -1-.
WARNING
risk of accidents.
Note


t equipment (radio, clock, power locks and windows,

Battery -A-.
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect > Disconnect the BatteryA (Versions 3 and 4).
Disconnect the Battery -A- (Versions 3 and 4).
WARNING

Unlock the positive pole cover of the Battery -A- and

suspend it in the direction of the -arrow-.
Release the securing nut -2- and remove the cable

(B+) -1-.
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect > Disconnect the BatteryA (Versions 3 and 4).
Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect > Connect the BatteryA (Versions 3 and 4).
Connect the Battery -A- (Versions 3 and 4).
Caution

of the Battery -A-.

of the Battery -A-.
WARNING
risk of accidents.
Note


t
Battery -A-.
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect > Connect the BatteryA (Versions 3 and 4).
WARNING
Loosen securing nut -arrow- and remove earth wire

terminal -1- from the negative pole on Battery -A- .
Press locks -arrows- and tilt the positive battery pole

cover upwards -1- on the Battery -A-.
Loosen securing nut -1- from positive wire -2-.

Release the fastening blocks of the fuse carrier, and
remove it.
Remove cable (B+) -2-.
Vehicle electrics
Vehicle electrics
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>
Caution
Fit the positive wire terminal to the positive Battery -A- pole and tighten the fastening screw with the indicated
tightening torque Chapter.
Fit the earth wire terminal to the negative pole

Battery -A- and tighten the fastening screw with the
indicated tightening torque Chapter.
WARNING
risk of accidents.
Note


t
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install
Battery -A- - remove and install
Note
To remove the Battery -A-, it is not necessary to remove the fuse box, just move it to the right, respecting the cable
clearance.
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Remove the BatteryA (Version 1).
Remove the Battery -A- (Version 1).

Disconnect the Battery -A- Chapter.
Loosen fastening bolt -1- of the Battery -A-tray.

Remove the fastening support -2- of the Battery -A-.
Remove the Battery -A- from its housing.
Vehicle electrics
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Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Install the BatteryA (Version 1).
Install the Battery -A- (Version 1).
Note
The differences between Batteries -A- will be reduced through a floor frame adapter, as well as a ventilation cover
for degassing. The instructions for installing the ventilation cover for degassing and the floor frame adapter are
provided together with the Battery -A-.
Install the Battery -A- so that the base frame fits

below the support projections -arrows- of the
Battery -A-tray.
The Battery -A- is properly installed when the central

slot (recess) in the Battery -A- base is aligned with the
threaded hole in the Battery -A- support -arrows-.
In Batteries -A- with flexible tube for central
degassing, pay attention so the flexible tube is not
disconnected. This is the only way the Battery -Acan be freely degassed.
In Batteries -A- without flexible tube for central

degassing, make sure that the opening on the upper
cover section is not clogged.
Install the fastening handle -2- and tighten the
fastening screw -1- with the specified torque
Chapter.
Connect the Battery -A- Chapter.
Vehicle electrics
Vehicle electrics
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>


Remove the fastening support -2- of the Battery -A-.
Vehicle electrics
Vehicle electrics
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>
Note
The diversity of batteries will be reduced through a floor frame adapter, as well as a ventilation cover for degassing.
The instructions for installing the ventilation cover for degassing and the floor frame adapter are provided together
with the Battery -A-.
Install the Battery -A- so that the Battery -A- base

frame fits below the support projections -arrows- of
the Battery -A-.

Install the fastening support -2- and tighten the

Chapter.
Connect Battery -A- Chapter.
Vehicle electrics
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Vehicle electrics
>


Release the fuse holder fastening locks -arrows- for
the Battery -A-console.
Move the fuse holder support to the side, releasing
it for removing the Battery -A-.
Remove the thermal protection from the Battery -A.

Remove the fastening support -2-.
Vehicle electrics
Vehicle electrics
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Note

the Battery -A-.



Chapter.
Install the thermal Battery -A-protection.
Install the fuse holder support claws to the Battery A-console, along with the respective terminals arrows-.
Vehicle electrics
Vehicle electrics
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>

Release the fuse holder fastening locks -arrows- for

the Battery -A-console.
Move the fuse holder support to the side, releasing
it for removing the Battery -A-.
Remove the thermal protection from the Battery -A(if any).

Remove the Battery -A-.
Vehicle electrics
Vehicle electrics
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>
Note

the Battery -A-.



Chapter.
Install the thermal Battery -A-protection.
Install the fuse holder support claws to the Battery A-console, along with the respective terminals arrows-.
Vehicle electrics
>
Vehicle electrics
>

Release locks -arrows- and remove fuse carrier -1from Battery -A-console-2-.
Loosen fastening bolt -1- of the support -2- of

Battery -A-.
Remove the Battery -A-.
Vehicle electrics
Vehicle electrics
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>
Note

the Battery -A-.
The Battery -A- is properly installed when the centre

threaded hole in the Battery -A- tray -arrows-.
In Batteries -A- with flexible tube for centre
In Batteries -A- without flexible tube for centre


Chapter.
Install the fuse carrier -1- on the Battery -A- .

After installation, check the correct Battery -Afastening. If the Battery -A- is not firmly fastened,
the following may happen:
The Battery -A- service life may be reduced due to
vibration.
l There may be damage to the Battery's -A-case.

l Safety issues in case of collision.
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA console - remove and install
Battery -A- console - remove and install
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA console - remove and install > BatteryA console (version 1) - remove and install
Battery -A- console (version 1) - remove and install

Removal:
Disconnect and remove Battery -A- Chapter.
Remove the plastic strap -1- that fastens the cables

on the front part of the Battery -A-console.
Loosen the securing nuts -1- (16 Nm) and fastening

screw -2- (16 Nm) from the Battery -A-console-3-.
Remove the flexible rubber draining tube from the
lower part of the Battery -A-console.
Remove the Battery -A-console-3- from its housing.
Installation:
Installation is performed in reverse sequence to the
removal, considering the following:
Tighten the securing nuts -1- and the fastening

screw -2- to the specified torque Chapter.
After installing, check correct seating of the Battery A- on its console.
Vehicle electrics
Vehicle electrics
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Battery -A- console (version 2) - remove and install

Removal:
Disconnect and remove Battery -A- Chapter.
Remove air filter Engine; Rep. gr.24.
Loosen securing nuts -1- and fastening screw -2from the Battery -A-console-3-.
Remove the flexible rubber draining tube from the
lower part of the Battery -A-console.
Remove the Battery -A-console-3- from its housing.
Installation:
Tighten the securing nuts -1- and the fastening screw

-2- to the specified torque Chapter.
After installing, check correct seating of the Battery A- on its console.
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > Tightening torques - Battery
Tightening torques - battery
Location
Tightening torques
Terminals in battery poles
6 Nm
Auxiliary terminal to battery terminal 6 Nm

Fastening support screw
25 Nm
securing nut for battery console
16 Nm
Fastening screw for battery console 16 Nm
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > Tightening torques - Battery
>
Electrical system > Starter-current supply -CC > Starter
Starter
WARNING
Before executing any work on the electric system, it is necessary to disconnect the battery -A- Chapter earth
cable.
Note
t
Check whether the vehicle has a coded radio. If so, request the anti-theft code before disconnecting the Battery -Aearth wire.
Safe working conditions for repairing the electrical system are created by disconnecting the ground cable from the
When the Battery -A-earth wire is reconnected, check vehicle equipment (radio, clock, centre locking, electric
windows, etc.) according to the Workshop Manual and/or instructions for use.
Vehicle electrics
>
Electrical system > Starter-current supply -CC > Starter > StarterB - remove and install
Starter -B- - remove and install

t Torque wrench - 5 to 50 Nm ( enc. 1/2") -VAG 1331-
t Torque wrench 40 - 200 Nm -VAG 1332-
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Starter > StarterB - remove and install
>
Electrical system > Starter-current supply -CC > Starter > StarterB - remove and install > StarterB for vehicles with 1.0l, 1.6l and 2.0l engines (ARA,
BAH, BPA, CCRA, BBX, CFEA)
Starter -B- for vehicles with 1.0l, 1.6l and 2.0l engines (ARA, BAH, BPA, CCRA, BBX, CFEA)
Removal:
Turn off the ignition, all the electrical devices, and remove the key from ignition.
Put the vehicle on a lift in order to make the operation easier.
Remove the lower engine noise insulation, if necessary General body repairs, exterior; Rep. gr.50.
Remove gearbox selector lever Clutch and transmission; Rep. gr.34.
Remove securing nut-3- (15 Nm) below the Starter -B- and remove cable support -1-.
Remove the fastening screw -2- (80 Nm) for the

Starter -B-.
Disconnect terminal 50 -1- from Starter -B-.

Remove the plastic cover -2- and remove the
positive wire -3- from the magnetic switch.
Remove hexagonal nut -5- (15 Nm).
Remove earth wire -4- and loosen the hex head
screw (80 Nm).
Remove the Starter -B-.
Installation:
removal, observing the following:
Tighten the fastening screws and nuts of the Starter
-B- with the specified tightening torque Chapter.
Vehicle electrics
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Electrical system > Starter-current supply -CC > Starter > StarterB - remove and inst all > StarterB for vehicles with 1.0l, 1.6l and 2.0l engines (ARA,
BAH, BPA, CCRA, BBX, CFEA)
Vehicle electrics
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Electrical system > Starter-current supply -CC > Starter > StarterB - remove and install > StarterB for vehicles with 1.4l engines (BBZ, BBY, BKY)
Starter -B- for vehicles with 1.4l engines (BBZ, BBY, BKY)
Removal:
Remove the Battery -A-support.
Remove the lower engine noise insulation, if necessary General body repairs, exterior; Rep. gr.50.

Remove the plastic cover -2- and remove the duct 1- from the magnetic switch.
Remove the securing nut -5- and remove the ground
strap -7-.
Loosen the fastening screw -6 and 8- for the Starter

-B-.
Installation:
Vehicle electrics
Vehicle electrics
>
Electrical system > Starter-current supply -CC > Starter > StarterB - remove and install > StarterB for vehicles with 1.4l engines (BBZ, BBY, BKY)
>
Electrical system > Starter-current supply -CC > Starter > StarterB - remove and install > StarterB for vehicles with 1.4l engine (BAY)
Starter -B- for vehicles with 1.4l engine (BAY)

Removal:
Remove engine cover panel in the direction of the arrows-.

Release the securing nut -2- and remove the
positive wire.
Loosen securing nut -arrow- and remove the ground

strap.
Loosen the upper fastening screw -arrow- for the

Starter -B-.
Remove the lower engine noise insulation
General body repairs, exterior; Rep. gr.50.
Loosen the securing nut -2- (15 Nm) and remove the
support -2-.
Loosen the lower fastening screw -arrow- for the
Starter -B-.
Installation:
Vehicle electrics
Vehicle electrics
>
Electrical system > Starter-current supply -CC > Starter > StarterB - remove and install > StarterB for vehicles with 1.4l engine (BAY)
>
Electrical system > Starter-current supply -CC > Starter > StarterB - remove and install > StarterB for vehicles with 1.9l engine (ASY)
Starter -B- for vehicles with 1.9l engine (ASY)

Removal:

Remove the plastic cover -2- and remove the
positive wire -3- from the magnetic switch.
Remove hexagonal nut -5- (15 Nm).

Remove earth wire -4- and loosen the hex head
screw (80 Nm).
Remove the lower engine noise insulation, if

necessary General body repairs, exterior; Rep.
gr.50.
Loosen the securing nut -3(15 Nm) and remove the

support -2-.
Loosen the lower fastening
screw -arrow- for the
Starter -B-.

Installation:
Installation is performed in
reverse sequence to the
removal, considering the
following:
Tighten the fastening
screws and nuts of the
Starter -B- with the

specified tightening torque
Chapter.
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Starter > StarterB - remove and install > StarterB for vehicles with 1.9l engine (ASY)
Electrical system > Starter-current supply -CC > Starter > StarterB - (Manufacturer Valeo) - disassemble and assemble
Starter -B- - (Manufacturer Valeo) - disassemble and assemble
1 - Starter -Bq Remove and install Chapter.

2 - Lever
3 - Mobile core
4 - Magnetic switch
q Remove and install Chapter.
5 - Hexagonal nut
q 9.5 Nm.
6 - Starter -B-cover
7 - Screw
q 3.3 Nm.
8 - Screw
q 6.4 Nm.
9 - Brush holder
10 - Coil (Polar case)
11 - Gearing pinion and armature assembly
12 - Drive bearing
13 - Screw
q Used to fasten the magnetic wrench.
3.75
Nm.
Vehicle electrics
>
Electrical system > Starter-current supply -CC > Starter > StarterB - (Manufacturer Valeo) - disassemble and assemble > Magnetic switch - remove
and install
Magnetic switch - remove and install

Removal:
Remove the Starter -B- Chapter.
Loosen the securing nut -arrow- (9.5 Nm) and

disconnect the brush cable.
Remove the fastening screws -arrows- (3.75 Nm)

from the magnetic switch.
Note
Use a good quality wrench. If removal is difficult, hit
the screw heads sharply a few times with a pointed
punch.
Remove the magnetic switch.
Installation:
removal.
Install the spring and the magnetic switch and

tighten the magnetic switch fastening screws (3.75
Nm).
Connect the brush cable by fastening it with the nut

tightened to (9.5 Nm).
Install the Starter -B- Chapter.
Vehicle electrics
>
Electrical system > Starter-current supply -CC > Starter > StarterB - (Manufacturer Valeo) - disassemble and assemble > Magnetic switch - remove
and install
Vehicle electrics
pinion -
> Electrical system > Starter-current supply -CC > Starter > StarterB - (Manufacturer Valeo) - disassemble and assemble > Armature and gearing
remove and install
Armature and gearing pinion - remove and install

t Pressure pipe -VW 420Removal:

Turn off the ignition and all electrical equipment,
and remove the key from ignition.
Remove the magnetic switch Chapter.
Loosen the fastening screws -arrows- (3.3 Nm) from

the rear cover of the shaft end.
Remove lock washer, flat washer, and sealing ring.
Remove fastening screws for the polar case cover

cap -arrows- (6.4 Nm) and remove the cover.
Using the Pressure tube -VW 420- as a guide, slide

the brush holder -arrow- and remove it from the
armature.
Note
Handle carefully, because the springs may jump out of
the brush holder.
Remove the polar case by pulling it out.
Note
Please be very careful with your fingers, as the
armature is strongly pulled by the magnets.
Remove the armature and gearing pinion.
Installation:
Fit the armature -arrow- to the activation bearing,

together with the operating rod and rubber stop.
Fit the polar case.
Note
Fit the brush holder using the Pressure tube -VW

420- and slide it toward the rotor -arrow-, then
remove the tool.
Install rear cover, paying attention to the correct

position of tab and the cover screw holes.
Place cable seal rubber on the case cover -1-.
Fit seal -4-, plain washer -3- and circlip -2- on
armature shaft.
Note
If you are unable to easily fit the circlip, pull the shaft a
little outwards.
Install the rear axle end cover and tighten the screws
-arrows- to a (3.3-Nm) torque.
Install the fastening screws -arrows- of the polar

case cover cap by applying a (6.4-Nm) torque.
Install the magnetic switch Chapter.
Vehicle electrics
pinion -
> Electrical system > Starter-current supply -CC > Starter > StarterB - (Manufacturer Valeo) - disassemble and assemble > Armature and gearing
remove and install
Vehicle electrics
>
Electrical system > Starter-current supply -CC > Starter > StarterB - (Manufacturer Bosch) - disassemble and assemble
Starter -B- - (Manufacturer Bosch) - disassemble and assemble
1 - Starter -Bq Remove and install Chapter.

2 - Magnetic switch
3 - Hexagonal nut
q 8 Nm.
4 - Operating rod
5 - Rubber stopper
6 - Gearing pinion
q Remove and install (Fastened on planetary gear shaft) Chapter.
7 - Planetary gear
8 - Armature
9 - Gearing pinion
q Remove and install (Fastened on armature shaft) Chapter.
10 - Armature
11 - Screw
q 2 Nm.
12 - Screw
q 6 Nm.
13 - Starter -B-cover
14 - Brush holder
15 - Coil (Polar case)
16 - Circlip and capsule
17 - Drive bearing
18 - Repair set (metal cover, bearing bush, sealing ring)
19 - Screw
q Used to fasten the magnetic wrench.
q 7 Nm.
Vehicle electrics
>
Electrical system > Starter-current supply -CC > Starter > StarterB - (Manufacturer Bosch) - disassemble and assemble > Magnetic switch - remove
and install
Magnetic switch - remove and install

Removal:
Remove the securing nut -arrow- (8 Nm) and

disconnect the brush cable.
Remove the fastening screws -arrows- (7 Nm) from

the magnetic switch.
Note
Please use a good quality cross-slotted screwdriver. If
removal is difficult, hit the screw heads sharply a few
times with a pointed punch.
Remove the magnetic switch.
Remove the spring and the rod operating plunger arrow-.

Installation:
Install plunger onto operating rod.
Install spring and magnetic key, fastening the screws
with torque (7 Nm).
Connect the brush cable, fastening the nut to a 8Nm torque.
Vehicle electrics
and install
>
Electrical system > Starter-current supply -CC > Starter > StarterB - (Manufacturer Bosch) - disassemble and assemble > Magnetic switch - remove
Vehicle electrics
>
Electrical system > Starter-current supply -CC > Starter > StarterB - (Manufacturer Bosch) - disassemble and assemble > Armature - remove and
install
Armature - remove and install

t Device -VW 463/4-.
t Torque wrench 2 to 10 Nm -VAG 1783-.

Removal:
Remove the magnetic switch Chapter.
Remove shaft end rear cover, circlip, plain washer,
and sealing ring.
Remove the fastening screws -arrows- (6 Nm) from

the polar case cover cap.
Using the Device -VW 463/4- as a guide, slide the

brush holder -arrow- and remove it from the
armature.
Remove the armature from the polar case by pulling

it.
Note
Remove the rubber buffer -arrow-.

Installation:
Install the armature in the activation bearing and in
the polar case.
Fit the armature -arrow- to the activation bearing,

together with the operating rod and rubber buffer.
Note
Fit the brush holder -arrow- using the Device -VW

463/4-, sliding it toward the rotor, and then
removing the tool.
Place the housing cable seal rubber -1-.

Install rear cover, paying attention to the correct
position of tab and the cover screw holes.
Fit seal -4-, plain washer -3- and circlip -2- on
armature shaft.
Note
If you are unable to easily fit the circlip, pull the shaft a
little outwards.
Install rear axle end cover -1- and tighten the screws
with a (2-Nm) torque.
Install and tighten fastening screws -2- of the polar
case cover cap by applying a (6-Nm) torque.
Install the magnetic switch Chapter.
Vehicle electrics
>
Electrical system > Starter-current supply -CC > Starter > StarterB - (Manufacturer Bosch) - disassemble and assemble > Armature - remove and
install
Vehicle electrics > Electrical system > Starter-current supply-CC > Starter > StarterB - (Manufacturer Bosch) - disassemble and assemble > Gearing pinion (Fastened
on armature shaft) - remove and install
Gearing pinion (Fastened on armature shaft) - remove and install

t Assembly tool -EQ-7331/1t Assembly tool -EQ-7331/2t Lock puller -EQ-7331/3t Pressing tool -EQ-7331/4Removal:
Remove the armature Chapter.
WARNING
When setting the armature on the vise, please be
careful not to damage the magnets. Should any
damage occur, the armature must be replaced.
Remove metallic cover -arrowwith the Assembly

tool -EQ-7331/1-.
Lower the fastening capsule of the circlip by using a

tube with diameter (13 mm)-arrow-, tapping slightly
on the tube with a rubber or wooden hammer until
displacing the capsule from the circlip.
Use pliers or a screwdriver to remove the circlip and
capsule from the armature shaft.
Remove the gearing pinion -arrow - from the

armature shaft.
Installation:
WARNING
Whenever the gearing pinion is being repaired, please
replace the components below: metallic cover, circlip
and capsule.
Secure slightly the armature on the vise.
WARNING
When setting the armature on the vise, please be
careful not to damage the magnets. Should any
damage occur, the armature must be replaced.
Install the gearing pinion in the armature shaft.
Fit the buffer capsule on the armature shaft.
Note
Observe that the buffer capsule has an assembling
side.
Mount the circlip on shaft.
Fit the circlip on the shaft notch by using the Lock

puller -EQ-7331/3- and tapping slightly with a
hammer towards -arrow-.
Mount the Assembly tool -EQ-7331/2- on the

gearing pinion and secure the assembly on the vise.
To encapsulate the circlip in the fastening capsule,

use the Lock puller -EQ-7331/3--3- and tap slightly
with a hammer towards -arrow- until fitting.
Install the metallic cover-arrow-.
Use the Assembly tool -EQ-7331/1--1- to drive the

metallic cover on the gearing pinion.
Install the armature Chapter.
on armature shaft) - remove and install
on planetary shaft) - remove and install
Gearing pinion (Fastened on planetary shaft) - remove and install

Removal:
Remove the armature Chapter.
Remove metallic cover -arrowwith the Assembly

tool -EQ-7331/1-.
Lower the fastening capsule of the circlip by using a

tube with diameter (13 mm)-arrow-, tapping slightly
on the tube with a rubber or wooden hammer until
displacing the capsule from the circlip.
By using pliers or a screwdriver, remove the circlip
and capsule from the planetary shaft.
Remove the gearing pinion -arrow - from the

planetary shaft.
Installation:
WARNING
Whenever the gearing pinion is being repaired, please
replace the components below: metallic cover, circlip
and capsule.
Check the conditions of the existing bushing on the
planetary gear. If the inside diameter is greater than
8.12 mm, Bosch recommends the component
replacement.
Install the gearing pinion on the planetary shaft.
Fit the stop capsule on the planetary shaft.
Note
Observe that the buffer capsule has an assembling
side.
Mount the circlip on shaft.
Fit circlip on the shaft notch by using theLock puller EQ-7331/3--3- and tapping slightly with a hammer
towards -arrow-.
To encapsulate the circlip in the fastening capsule,

use the Lock puller -EQ-7331/3--3- and tap slightly
with a hammer towards -arrow- until fitting.
Install the metallic cover-arrow-.
Use the Assembly tool -EQ-7331/1--1- to drive the

metallic cover on the gearing pinion.
Install the armature Chapter.
on planetary shaft) - remove and install
Vehicle electrics
>
Electrical system > Starter-current supply -CC > Starter > StarterB - (Manufacturer Bosch) - disa ssemble and assemble > Bearing bush - remove and
install
Bearing bush - remove and install

t Plate -VW 401t Pressure pin -VW 407t Pressure pin -VW 411t Pressure disc -VW 412t Pressure base -VW 432t Base -VW 295A-
t Pressing tool -EQ 7331/4-
Bearing bush removal:
Support the case on Plate -VW 401- and remove the

bearing bush with the circlip.
Bearing bush installation:
Install the bushing on case to the stop, by using the

Pressure pin -VW 407-.
Sealing ring installation:
Fit sealing ring on case.
Support case on the Plate -VW 401- and re-drive by

using the Pressing tool -EQ-7331/4-.
Vehicle electrics
>
Electrical system > Starter-current supply -CC > Starter > Tightening torques - Starter
Tightening torques - Starter

Location
Tightening torques
Starter to transmission
M12
80 Nm
Starter to transmission
M10
40 Nm
Earth wire
M8
15 Nm
Cable support
M8
15 Nm
positive wire to electromagnetic switch M8
15 Nm
Vehicle electrics
>
Electrical system > Starter-current supply -CC > Alternator
Alternator
WARNING
cable.
Note
t
Check Generator (Alternator) -C-: Manual "Current flow diagram", Troubleshooting in the Electrical System and
Installation Locations.
Vehicle electrics
>
Electrical system > Instruments, GCI > Combined instrument
Combined Instrument
General description:
The Combined instrument -K- has the following components:
t Control unit with indicator in the combined instrument -J285t Immobilizer control unit -J362t Speedometer -G21t Rev counter -G5t Fuel level indicator -G1t Coolant temperature gauge -G3t Multi-function indicator
t Control light symbols Chapter.
The instrument panel is also fitted with a sound alarm activated by the Control unit with indicator in the combined
instrument -J285- which emits a sound signal in addition to the visual signals given by some indicators.
All the light displays are equipped with light emitting diodes (LEDs). No repair work is expected for the Combined
instrument -K-. If necessary, replace the entire Combined instrument -K- Chapter.
Vehicle electrics
>
Electrical system > Instruments, GCI > Combined instrument > Locating defects and indicating faults
Locating defects and indicating faults

The Combined instrument -K- is equipped with self-diagnosis function.
For troubleshooting, use the Vehicle diagnostic, testing

and information system -VAS 5051- or the Vehicle
diagnosis and technical information system -VAS 5052or later equipment.
Connect the Vehicle diagnostic, testing and

information system -VAS 5051- or the Vehicle
diagnosis and technical information system -VAS
5052- or later equipment General
information; Rep. gr.97 on 16-pin diagnostic
connection -T16--arrow-.
Turn on the ignition.
Turn off all electrical equipment.
Proceed by selecting the desired functions
Vehicle diagnostic tester.
Vehicle electrics
Vehicle electrics
>
Electrical system > Instruments, GCI > Combined instrument > Locating defects and indicating faults
>
Electrical system > Instruments, GCI > Combined instrument > Combined instrumentK - replace
Combined instrument -K- - replace
WARNING
cable.
Note
t
t Before removing the Combined instrument -K-, follow the notes and work instructions for troubleshooting.
t

t Vehicle diagnostic, testing and information system -VAS 5051-
t Vehicle diagnosis and technical information system -VAS 5052t Vehicle diagnostic, testing and information system -VAS 6150t Diagnostic cable -VAS 5051/6Bt Diagnostic cable -VAS 5052/3At Wireless diagnostic connector -VAS 5054A-
The work sequence Combined instrument - replace includes the following works:
When installing a new Combined instrument -K-, it is necessary to adjust the Control unit w/ indicator on the
combined instrument -J285- to the different equipment features and corresponding country-related variations.
To adapt the Immobilizer control unit -J362- to the Engine control unit -J623-, save the Engine control unit -J623data in the replacement Combined instrument -K- .
t After installing a new Combined instrument -K-, it is necessary to adapt all keys of the vehicle.
To adapt, use the Vehicle diagnostic, testing and information system -VAS 5051- or Vehicle diagnosis and technical
information system -VAS 5052- or later equipment.
Connect the Vehicle diagnostic, testing and

information system -VAS 5051- or the Vehicle
diagnosis and technical information system -VAS
5052- or later equipment General
information; Rep. gr.97 on 16-pin diagnostic
connection -T16--arrow-.
Turn on the ignition.
Turn off all electrical equipment.
Proceed by selecting the desired functions
Vehicle diagnostic tester.
Vehicle electrics
>
Electrical system > Instruments, GCI > Combined instrument > Combined instrumentK - replace
Vehicle electrics
>
Electrical system > Instruments, GCI > Indication of Service Interval
Indication of
Service Interval
The electronic system for the service interval indicator interprets the data from a time counter and two distance
counters, and informs the user after a given time interval has elapsed or a given distance has been traveled.
Vehicle electrics
>
Electrical system > Instruments, GCI > In dication of Service Interval > Service interval indication - reset to zero
Service interval indication - reset to zero

Please Refer to Manual Booklet.
Vehicle electrics
>
Electrical system > Instruments, GCI > Cigarette lighter and 12V socket
Cigarette lighter and 12V socket
Vehicle electrics
>
Electrical system > Instruments, GCI > Cigarette lighter and 12V socket > Cigarette lighterU1 and 12V socketU5 - general overview of assembly
Cigarette lighter -U1- and 12V socket -U5- - general overview of assembly
1 - Cigarette lighter -U12 - 12 Volt socket -U5q Remove and install Chapter.
3 - Tensioning bushing
4 - Front upper centre console
q Remove and install Body - Internal assembly works; Rep. gr.68.
Vehicle electrics
>
Electrical system > Instruments, GCI > Cigarette lighter and 12V socket > Cigarette lighterU1 and 12V socketU5 - general overview of assembly
Vehicle electrics
>
Electrical system > Ins truments, GCI > Cigarette lighter and 12V socket > Cigarette lighterU1 and 12V socketU5 - remove and instal l
Cigarette lighter -U1- and 12V socket -U5- - remove and install
WARNING
cable.
Note
t
t Puller -T40148-
Vehicle electrics
Vehicle electrics
>
>
Electrical system > Instruments, GCI > Cigarette lighter and 12V socket > Cigarette lighterU1 and 12V socketU5 - remove and install
Electrical system > Instruments, GCI > Cigarette lighter and 12V socket > Cigarette lighterU1 and 12V socketU5 - remove and install > Removal
Removal
Note
The tensioning bushing does not need to be removed for removal of the 12 volt socket -U5-. For improved viewing,
it is represented outside the instrument panel.
WARNING
Observe the correct insertion of the Extractor -T40148- in the 12 volt socket -U5-, otherwise the locks will not be
disengaged and there is a risk that it will be damaged.
Note
A Wedge -T40148/1--2- for improved support in the

removal of the 12 volt socket -U5-.
Open the lid of the central console and remove the
cigarette lighter.
Insert the Puller -T40148- according to -arrow- so

that the protrusions -1- engage correctly in the
notches -2- of the 12 volt socket -U5-.
Disengage the 12 volt socket -U5--1- from the

tensioning bushing according to -arrow-.
WARNING
At the moment of removal of the 12 volt socket -U5from the instrument panel, observe the compression
of the harness of the panel.
Carefully remove the 12 volt socket -U5- from the

central console and disconnect the respective
connector.
In order to remove the 12 volt socket -U5--2- from

the Puller -T40148- press it according to -arrow A
and then turn the area -3- in the anti-clockwise
direction according to -arrow B-, thus disengaging the
protrusions -1-.
Vehicle electrics
Vehicle electrics
>
>
Electrical system > Instruments, GCI > Cigarette lighter and 12V socket > Cigarette lighterU1 and 12V socketU5 - remove and install > Removal
Electrical system > Instruments, GCI > Cigarette lighter and 12V socket > Cigaret te lighterU1 and 12V socketU5 - remove and install > Installation
Installation
Installation is performed in reverse sequence to the removal, considering the following:
Observe the correct

assembly position in the
detail.
Vehicle electrics
Vehicle electrics
>
>
Electrical system > Instruments, GCI > Cigarette lighter and 12V socket > Cigarette lighterU1 and 12V socketU5 - remove and install > Installation
Electrical system > Windscreen wipe/wash system > Windscreen wiper system
Windscreen wiper system
WARNING
cable.
Note
t
t Safe working conditions for repairing the electrical system are created by disconnecting the earth wire from the

t Torque Wrench - 4 to 20 Nm ( enc. 3/8") -VAG 1410t Torque wrench - 5 to 50 Nm ( enc. 1/2") -VAG 1331t Removal lever -80-200-
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper system - assembly overview
Windscreen wiper system - assembly overview
1 - Windscreen wiper blade

q Adjust the application angle Chapter.
2 - Windscreen wiper arm
q Adjust the resting position Chapter.
3 - Protection covers
4 - Hexagonal nut
q 20 Nm.
5 - Screw
q 5 Nm.
6 - Windscreen wiper mechanism
7 - Windscreen wiper motor -Vq Remove and install Chapter.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper blade - remove and install
Windscreen wiper blade - remove and install
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper blade - remove and install > Windscreen wiper
blade
Windscreen wiper blade

Removal:
Place arms in service/winter position.
The service/winter position is activated when the

windscreen wiper lever is activated in timer
operation position within 10 seconds after turning the
ignition off Vehicle instruction manual.
Raise the windscreen wiper arm.
Press the blade lock -arrow- and pull it down

towards the windscreen wiper arm.
Release the blade from the windscreen wiper arm,
and remove it.
Installation:
removal.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper blade - remove and install > Windscreen wiper
blade
Vehicle electrics > Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper blade - remove and install > Windscreen wiper
blade - streamlined (version 1)
Windscreen wiper blade - streamlined (version 1)

Removal:

Turn the windscreen wiper blade -1- on the wiper

arm towards running direction -arrow A-.
Remove the windscreen wiper blade -1- from the
wiper arm towards -arrow B-.
Installation:
removal.
Windscreen wiper blade - streamlined (version 2)

Removal:

Press button -1- and pull the wiper blade support -3removing it in the direction of the -seta- wiper arm 2-movement.
Installation:
removal.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper blade and arm set - remove and install
Windscreen wiper blade and arm set - remove and install


1331-
t Puller -T10369/1- or Gedore mini-puller -8562-1-
Vehicle electrics
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper blade and arm set - remove and install
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper blade and arm set - remove and install >
Removal
Removal
Note
Before removing the windscreen wiper arms, please check if the windscreen wiper motor -V- is in the rest position.
This is the only way to adjust the correct arm resting position during the installation.
Remove the protection covers carefully -arrowswith a screwdriver.
Loosen hexagonal nuts -arrows-, but do not remove

them completely.
Fit the Puller -T10369/1--2- on the windscreen wiper

arm -5-.
WARNING
Take care that the Puller -T10369/1--2- is fit
adequately on the windscreen wiper arm -5-, so that is
does not damage the drive axle -4-.
Support the lower base of the fuse -3- on the drive
axle -4- of the windscreen wiper arm -5-.
Turn the fuse -1- clockwise, until the windscreen
wiper arm -5- is released from the drive axle -4-.
Remove the Puller -T10369/1-, remove the securing
nuts and remove the windscreen wiper arm.
Vehicle electrics
>
>
Removal
Vehicle electrics
Installation
Installation
Installation is performed in reverse sequence to that of removal, observing the following:
Fit the windscreen wiper arms near their resting positions and manually tighten the securing nuts.
Adjust the blades' resting position Chapter.
Tighten the securing nuts -arrows- to a (20 Nm)

torque.
Vehicle electrics
>
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper mechanism - remove and install
Installation
Vehicle electrics
Windscreen wiper mechanism - remove and install
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper mechanism - remove and install > Remova l
Removal
Remove the windscreen wiper arm and blade set Chapter.
Remove lower cover from the windscreen frame General body repairs, exterior; Rep. gr.64.
Remove water tank Body - External assembly work; Rep. gr.50.
Remove the fastening screws-arrows- and pull off

the washers.
Remove the Windscreen wiper motor -V-connector.
Remove the windscreen wiper mechanism.
Vehicle electrics
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper mechanism - remove and install > Removal
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper mechanism - remove and install > Installation
Installation
Installation is performed in reverse sequence to that of removal, observing the following:
Position the windscreen wiper mechanism with the

windscreen wiper motor, and check that the guide
rubber -arrow- (for different versions) is assembled
so as to be placed over the pin.
Connect the connector to the wiper motor.
Place the washers and fasten the screws -arrows-.

Tighten the fastening screws to the specified torque
Chapter.
Install water tank Body - External assembly
work; Rep. gr.50.
Vehicle electrics
Vehicle electrics
>
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper mechanism - remove and install > Installation
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper motorV - disassemble and assemble
Windscreen wiper motor -V- - disassemble and assemble
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper motorV - disassemble and assemble >
Disassembly
Disassembly
Remove the windscreen wiper mechanism Chapter.
With the Removal lever -80-200-, remove first the

linkage bar -1- and, then, the linkage bar -2- from the
windscreen wiper mechanism handle.
Note
When removing the linkage bars, make sure that the
rubber joints from the ball articulation are not
damaged.
Loosen the securing nut -2- from the windscreen

wiper mechanism handle.
Remove the handle -3- from the windscreen wiper
motor support.
Loosen the fastening screws -1- from the Windscreen
wiper motor -V-.
Remove the windscreen wiper mechanism motor
from the respective arms.
Vehicle electrics
>
Disassembly
Vehicle electrics
>
Electrical system >
Windscreen wipe/wash system
>
Windscreen wiper system > Windscreen wiper motorV - disassemble and assemble >
Assembly
Assembly
Assembly is performed in the reverse order to disassembly, observing the following:
Note
Set the windscreen wiper motor -V- in its rest position.
Connect the Battery -A- Chapter.
Connect the Windscreen wiper motor -V- connector and operate the mechanism for a few seconds.
Place the Windscreen wiper motor -V- in the

respective mechanism and fasten with the fastening
screws -1- (7 Nm).
Tighten the fastening screws to the specified torque

Chapter.
Turn the Windscreen wiper motor -V- on until it
stops at the resting position.
With the handle-3- loosened, first tighten the

articulated rod -2- and then the articulated rod -1-.
Align the articulated rods -1 and 2- according to the
centre line indicated in the figure.
Tighten the securing nut for the crank -4- to (18 Nm).
Vehicle electrics
>
Assembly
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper blade resting position - adjust
Windscreen wiper blade resting position - adjust
Note
In vehicles with the steering wheel on the right, the windscreen wiper blades are arranged symmetrically.
Vehicle electrics
>
Electrical system >
Windscreen wipe/wash system
>
Windscreen wiper system > Windscreen wiper blade resting position - adjust > Driver's side
Driver's side
Vehicles ( 07/2006):
The distance -A-between the windscreen blade end
and the upper corner of the water deflector cover
must be of 20 + 10mm.
Vehicles (08/2006 ):
The distance -A- between the windscreen blade end
must be of 45 5mm.
If necessary, adjust the windscreen wiper blade
resting position by releasing and moving the arms.
Release the windscreen wiper arms Chapter.
Tighten the securing nuts to the specified torque
Chapter.
Vehicle electrics
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper blade resting position - adjust > Driver's side
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper blade resting position - adjust > Passenger's
side
Passenger's side
Vehicles ( 07/2006):
The distance -A-between the windscreen blade end
must be of 20 + 10mm.
Vehicles (08/2006 ):
The distance -B- between the windscreen blade end
must be of 45 5mm.
If necessary, adjust the windscreen wiper blade
resting position by releasing and moving the arms.
Release the windscreen wiper arms Chapter.
Tighten the securing nuts to the specified torque
Chapter.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper blade resting position - adjust > Passenger's
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Blade application angle on the windscreen - adjust
side
Vehicle electrics
Blade application angle on the windscreen - adjust
WARNING
For streamlinedwindscreen wiper blade, it is not necessary to check the wiper arm incidence angle, because they
cannot be modified or adjusted.
Only check the blade application angle when the wipers vibrate or make noises.
t Adjustment device -3358B Adjust the resting position of the windscreen wiper
arms Chapter.
Remove the blades from the windscreen wiper arms

Chapter.
Place the windscreen wiper arm-2- on the

Adjustment device -3358B- and fasten it with the
screw -3-.
Check the application angle according to the

following table:
Application angle (nominal values)

Left-hand drive vehicles Right-hand drive vehicles
Driver's side
-4,0
+4,0
Passenger's side
-1,0
+1,0
Tolerance
l If necessary, adjust the application angle to the nominal value as explained below:
Using a SW24 spanner -1-, tilt the windscreen wiper arm -2- according to the nominal value -arrows-.
Release the windscreen wiper arm -2- from the

Adjustment device -3358B- and fasten it again with
the screw -3-.
Compare the adjusted value with that given in the
table. If necessary, repeat the operation until
reaching the nominal value.
Remove the Adjustment device -3358B- and install

the windscreen wiper blade Chapter.
After adjusting, check the windscreen wiper
operation for occasional trembling movements.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Blade application angle on the windscreen - adjust
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Tightening torque - Windscreen wiper system
Tightening torque - Windscreen wiper system

Location
Tightening torques
Windscreen wiper arm and blade set M8
20 Nm
Windscreen wiper mechanism
5 Nm
Vehicle electrics
Vehicle electrics
M6
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Tightening torque - Windscreen wiper system
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Rain sensorG213 - remove and install
Rain sensor -G213- - remove and install
Note
t
When the Rain sensor -G213- is removed from its support in perfect conditions (e.g. when replacing windscreen),
it can be reinstalled.
Store the Rain sensor -G213- and keep it clean until the new installation, by preventing the padded silicone
coupling from being soiled.
t Scraper -VW 037-
Vehicle electrics
Vehicle electrics
Removal
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Rain sensorG213 - remove and install
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Rain sensorG213 - remove and install > Removal
Remove the rearview mirror General body repairs, interior; Rep. gr.68.
Unlock the locks -arrows- and remove the lower

cable duct -2- and the upper cable duct -1-.
Remove the Internal front light -W1- Chapter.
Pull off connectors -arrows-
Loosen the fastening clip -arrow- on the cable.
Remove the Rain sensor -G213--1- from the mirror

fastening support -2-.
Note
Carefully pull off the cable, avoiding damage to the
roof lining.
Vehicle electrics
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Rain sensorG213 - remove and install > Removal
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Rain sensorG213 - remove and install > Installation
Installation
Clean properly the windscreen by inside the support with Isopropanol (isopropyl ethanol).
Remove, if required, the protective cover from the new Rain sensor -G213- .
Note
t Pay attention in order not to soil the surface (coupling adhesive) of the Rain sensor -G213- during assembly.
When the surface (coupling adhesive) of the Rain sensor -G213- is soiled, it may be occasionally cleaned by
affixing and detaching one or more adhesive tape stripes.
After disassembly, no bubbles must remain between the windscreen and the coupling adhesive of the Rain sensor G213-.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Rain sensor and sunlight penetration photosensorG397 - remove
and install
Rain sensor and sunlight penetration photosensor -G397- - remove and install
Note
t
When the Rain sensor and sunlight penetration photosensor -G397- is removed from its support in perfect
conditions (e.g. when replacing windscreen), it can be reinstalled
Store the Rain sensor and sunlight penetration photosensor -G397- and keep it clean until the new installation, by
preventing the padded silicone coupling from being soiled.
t Scraper -VW 037- or
t Wedge -3409-
Vehicle electrics
>
and install
Vehicle electrics
and install
> Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Rain sensor and sunlight penetration photosensorG397 - remove
> Removal
Removal
Remove the rearview mirror General body repairs, interior; Rep. gr.68.
Disconnect connector -A- from Rain sensor and

sunlight penetration photosensor -G397--2-.
Remove the Rain sensor and sunlight penetration

photosensor -G397--1- from the support -2-, with
the help of the Scraper -VW 037- or the Wedge 3409-, lifting it in lever movement in slot -3-.
Note
During removal, do not lift only the upper lining of the
Rain sensor and sunlight penetration photosensor G397-, but rather the entire set.
Vehicle electrics
and install
> Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Rain sensor and sunlight penetration photosensorG397 - remove
> Removal
Vehicle electrics
>
and install > Installation
Installation
Clean properly the windscreen by inside the support with Isopropanol (isopropyl ethanol).
Remove, if required, the protective cover from the new Rain sensor and sunlight penetration photosensor -G397- .
Note
t
Pay attention in order not to soil the surface (padded coupling) of the Rain sensor and sunlight penetration
photosensor -G397- during assembly.
When the surface (padded coupling) of the Rain sensor -G397- is soiled, it may be occasionally cleaned by affixing
and detaching one or more adhesive tape stripes
After disassembly, no bubbles must remain between the windscreen and the padded coupling of the Rain sensor
and sunlight penetration photosensor -G397-
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen washer system
Windscreen washer system
WARNING
cable.
Note
t
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen washer system > Windscreen washer system - assembly overview
Windscreen washer system - assembly overview
Note
Illustrative figure, valid for all models.
1 - Washer jets
q Replace Chapter.
q Adjust Chapter.
2 - Windscreen and rear window washer pump -V59q Remove and install Chapter.
3 - Front washer pipe
q Connections General information; Rep. gr.92.
q Repair General information; Rep. gr.92.
4 - Connector for the Windscreen and rear window washer pump -V595 - Reservoir for the windscreen washer system
Vehicle electrics > Electrical system > Windscreen wipe/wash system > Windscreen washer system > Reservoir for the windscreen and rear window washer system
(version 1) - remove and install
Reservoir for the windscreen and rear window washer system (version 1) - remove and install
Vehicle electrics
> Electrical system > Windscreen wipe/wash system > Windscreen washer system > Reservoir for the windscreen and rear window washer system
(version 1) - remove and install > Removal
Removal
Remove the front bumper General body repairs, exterior; Rep. gr.63.
Disconnect the connector from the Windscreen washer pump -V5-.
Disconnect the connector -arrow- for the Water

level sensor for window washing -G33-.
Remove the securing nut -arrow- for the reservoir.

Remove the reservoir for the windscreen and rear
window washer system.
Vehicle electrics
> Electrical system > Windscreen wipe/wash system >

Windscreen washer system
>
Reservoir for the windscreen and rear window washer system
Vehicle electrics
(version 1) - remove and install > Installation
Installation
Tighten the securing nuts to the specified torque Chapter.
Note
When replenishing the reservoir. If fluid is used, refer to the mixture ratio in Booklet22.1.
Reservoir for the windscreen and rear window washer system (version 2) - remove and install
Vehicle electrics
Removal
Disconnect the connector from the Windscreen washer pump -V5-.
Remove the securing nut -arrow- (beside the

console of the Battery -A-).
Remove the securing nut -arrow- (below the

mounting point of the ground cable of the Battery A- on the body).
Remove the securing nut -arrow- (below the

headlight).
Remove the headlight Chapter.
Remove the reservoir for the windscreen and rear
window washer system.
Vehicle electrics
(version 2) - remove and install > Installation
Installation
Note
When replenishing the reservoir. If fluid is used, refer to the mixture ratio in Booklet22.1.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen washer system > Windscreen and rear window washer pumpV59 - remove and
install
Windscreen and rear window washer pump -V59- - remove and install
Vehicle electrics
install
>
> Removal
Removal
Remove the left wheel arch cover Body - External assembly works; Rep. gr.66.
Remove the connector and the hose connections in the pump.
Remove the pump from the support -arrow-.
Vehicle electrics
install
>
> Removal
Vehicle electrics
>
install > Installation
Installation
Installation is performed in reverse sequence to the removal.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen washer system > Tightening torque - windscreen and rear window washer
system
Tightening torque - windscreen and rear window washer system

Location
Tightening torque
Reservoir for the windscreen washer system M6
Vehicle electrics
>
5 Nm
Electrical system > Windscreen wipe/wash system > Windscreen washer system > Windscreen washer system washer je ts - replace
Windscreen washer system washer jets - replace
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen washer system > Windscreen washer system washer jets - replace > Removal
Removal
Loosen the hose connection from the washer jet -1-,

if necessary, disconnect the connector from the
heated washer jet (if any).
Press the washer jet towards -arrow- and remove it

downwards.
Vehicle electrics
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen washer system > Windscreen washer system washer jets - replace > Removal
>
Electrical system > Windscreen wipe/wash system > Windscreen washer system > Windscreen washer system washer jets - replace > Installation
Installation
Installation is performed in reverse sequence to the removal.
Note
After installing, use the adjustment procedures for the washer jets Chapter.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen washer system > Windscreen washer system washer jets - adjust
Windscreen washer system washer jets - adjust

Vehicle electrics > Electrical system > Windscreen wipe/wash system > Windscreen washer system > Windscreen washer system washer jets - adjust > Pre-adjusted
washer jets (fan- type nozzles)
Pre-adjusted washer jets (fan-type nozzles)

The washer jets are pre-adjusted, but small differences in height can be adjusted.
Note
t
If the spray jet is irregular or cannot be adjusted to the centre of the washer area, the nozzle must be replaced
(repair measure) Chapter.
Under no circumstances should needles or similar objects be used, since this might damage the nozzle's water
passage.
t The washer jets cannot be cleaned in the opposite direction of the jet, e.g., blowing from the front.
Nozzle jet position:

a - 491 + 76 mm
a - 491 - 190 mm
If the two action surfaces of the ejector jet are not
according to the dimensions -a -, the jet height must
be adjusted as explained below:
Adjust the jet through the nozzle tab-1- by moving it

slightly with your hand, upward or downward, with
the front bonnet closed.
Note
To perform the adjustment, support the ejector with
your hand to prevent it from moving from the housing.
Vehicle electrics > Electrical system > Windscreen wipe/wash system > Windscreen washer system > Windscreen washer system washer jets - adjust > Pre-adjusted
washer jets (fan- type nozzles)
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window wiper system
Rear window wiper system
WARNING
cable.
Note
t

1331-
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window wiper system
Polo Mk4
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window wiper system > Rear window wiper and washer system - assembly overview
Rear window wiper and washer system - assembly overview
1 - Protection cover
2 - Hexagonal nut
q 15 Nm.
3 - Rear window wiper arm
q Adjust Chapter.
4 - Sealing eyelet
q Replace if damaged.
5 - Washer jet
q Replace Chapter.
q Adjust Chapter.
6 - Sealing ring
7 - Rear window wiper motor -V12q Remove and install Chapter.
8 - Hexagonal nut
q 8 Nm.
9 - Rubber washer
10 - Spacer
11 - Rear window wiper blade
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window wiper system > Rear window wiper arm - remove and install
Rear window wiper arm - remove and install
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window wiper system > Rear window wiper arm - remove and insta ll > Removal
Removal
Raise the protective cover -1- of the rear window

wiper.
Lightly release the securing nut
Tilt the wiper arm and release it by means of
sideways movements in the cone.
Loosen the securing nut -arrow- and remove the
rear window wiper arm.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window wiper system > Rear window wiper arm - remove and install > Removal
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window wiper system > Rear window wiper arm - remove and install > Installation
Installation
Installation is performed in reverse sequence to the removal, observing the following:
To place the wiper motor in the end-of-course position, turn the rear window wiper switch on / off with the
ignition on.
Fit the wiper arm in the rest position and tighten the
securing nut -arrow- to the specified torque
Chapter.
Vehicle electrics
Vehicle electrics
>
>
Electrical system > Windscreen wipe/wash system > Rear window wiper system > Rear window wiper arm - remove and install > Installation
Electrical system > Windscreen wipe/wash system > Rear window wiper system > Rear window wiper motorV12 - remove and install
Rear window wiper motor -V12- - remove and install
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window wiper system > Rear window wiper motorV12 - remove and install > Removal
Removal
Remove rear window wiper arm Chapter.
Remove the rear lid lining General body repairs, interior; Rep. gr.70.
Disengage the connector -1- from the Rear window

wiper motor -V12-.
Pull off hose -2- from washer jet.
Loosen the hexagonal nuts -arrows- and remove the
Rear window wiper motor -V12-.
Upon removal, observe the sealing eyelet -arrow- to

keep it correctly fitted on the rear window.
Vehicle electrics
Vehicle electrics
>
>
Electrical system > Windscreen wipe/wash system > Rear window wiper system > Rear window wiper motorV12 - remove and install > Removal
Electrical system > Windscreen wipe/wash system > Rear window wiper system > Rear window wiper motorV12 - remove and install >
Installation
Installation
Installation is performed in reverse sequence to the removal, observing the following:
WARNING
Observe the correct assembly position for the sealing eyelet, in order to prevent water from infiltrating into the
vehicle.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window wiper system > Tightening torques - rear window wiper system
Tightening torques - rear window wiper system

Location
Tightening torques
Rear window wiper motor M6
8 Nm
Rear window wiper arm
12 Nm
Vehicle electrics
>
M8
Electrical system > Windscreen wipe/wash system > Rear window wiper system > Rear window wiper blade resting position - adjust
Rear window wiper blade resting position - adjust

Vehicles ( 07/06):
The distance -a- between the rear window wiper blade

lip and the lower edge of the window must be of 27
5 mm.
Vehicles (08/06 ):
The distance -a- between the rear window wiper blade

lip and the lower edge of the window must be of 44
5 mm.
If necessary, adjust the rear window wiper resting
position by moving the wiper rod.
Tighten the securing nut with the specified torque
Chapter.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window wiper system > Rear window wiper blade resting position - adjust
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window wiper system > Rear window wiper blade - remove and install
Rear window wiper blade - remove and install
Vehicle electrics > Electrical system > Windscreen wipe/wash system > Rear window wiper system > Rear window wiper blade - remove and install > Rear window
wiper blade (version 1)
Rear window wiper blade (version 1)

Removal:
Raise the rear window wiper arm.
Press the lock -arrow- and pull the blade -1- in the
direction -arrow-, and remove it.
Installation:
removal.
Rear window wiper blade (version 2)

Removal:
Raise the rear window wiper arm.
Hold the wiper arm and press, disengaging the cover

lid -1- in the direction of the -arrow-.
Remove the rear window wiper blade -1- in the

direction of the -arrow-.
Installation:
removal.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window washer system
Rear window washer system
WARNING
cable.
Note
t
The conditions for safe work on the electrical system are created by disconnecting the Battery -A- grounding cable
(interruption of the current).
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window washer system > Rear window washer system - assembly overview
Rear window washer system - assembly overview
1 - Washer jet
q Replace Chapter.
q Adjust Chapter.
2 - Rear window washer hose
q Connections General information; Rep. gr.92.
q Repair General information; Rep. gr.92.
3 - Windscreen washer pump -V5- and/or Rear window washer pump -V13q Remove and install Chapter.
4 - Windscreen washer pump -V5- and/or Rear window washer pump -V13-connector
5 - Reservoir for the windscreen and rear window washer system
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window washer system > Rear window washer system washer jet - replace
Rear window washer system washer jet - replace
Vehicle electrics
> El
ectrical system > Windscreen wipe/wash system > Rear window washer system > Rear window washer system washer jet - replace > Removal
Removal
Place the rear window wiper on the resting position.
Raise the protective cover -1- of the rear window washer system.
Carefully remove the washer jet towards the -arrowwith suitable pliers.
Vehicle electrics
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window washer system > Rear window washer system washer jet - replace > Removal
>
Electrical system > Windscreen wipe/wash system > Rear window washer system > Rear window washer system washer jet - replace > Installation
Installation
Insert the washer jet to the stop on the wiper shaft, so that the washer jet opening faces upwards.
Lower the protection cover.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window washer system > Rear window washer system washer jet - adjust
Rear window washer system washer jet - adjust

t Adjusting device -T 10127-
Note
If the washer jet jet is irregular or cannot be adjusted
t to the centre of the washer area, the washer jet
must be replaced (repair measure) Chapter.
Under no circumstances should needles or similar
objects be used (only the tool Adjusting device -T
t
10127- ), since this might damage the ejector washer
jet water passage.
Adjust the washer jet so the jet is sprayed to the
centre of the wiper action area.
The ejector water jet must point to the middle of the

area to be cleaned.
If necessary, adjust them with the Adjusting device
or 3019A -T 10127- or Adjusting device -3125A-.
Vehicle electrics
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window washer system > Rear window washer system washer jet - adjust
>
Electrical system > Lights, lamps, switches outside > Main headlights (?07/06)
Main headlights (07/06)
WARNING
cable.
Note
t Torque wrench 2 to 10 Nm -VAG 1783-
Vehicle electrics
Vehicle electrics
>
Electrical system > Lights, lamps, switches outside > Main headlights (?07/06)
>
Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Main headlights (?07/06) - general assembly overview
Main headlights (07/06) - general assembly overview
1 - Main headlight
q Correct the headlight assembly position Chapter.
q Check adjustment Chapter.
q Repair the fastening tabs Chapter.
2 - Left low-beam headlight lamp -M29- and/or Right low-beam headlight lamp -M31q Incandescent lamp H7, 12V - 55W.
q Replace Chapter.
4 - Left front indicator light lamp -M5- and/or Right front indicator light lamp -M7-
q Incandescent lamp 12V, 21W, yellow glass.

q Replace Chapter.
5 - Turn indicator bulb carrier
7 - Left high-beam headlight lamp -M30- and/or Right high-beam headlight lamp -M32q Incandescent lamp H1, 12 V - 55 W
q Replace Chapter.
8 - Left front sidelight lamp -M1- and/or Right front sidelight lamp -M3q Incandescent lamp W5W, 12V - 5W.
q Replace Chapter.
9 - Left headlight beam reach control motor -V48- and/or Right headlight beam reach control motor -V49q Located in the headlight compartment.
q Manufacturer - automotiv lighting - remove and install Chapter.
q Manufacturer - Valeo - remove and install Chapter.
Vehicle electrics
>
Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Main headlights (?07/06) - remove and install
Main headlights (07/06) - remove and install
Vehicle electrics
>
Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Main headlights (?07/06) - remove and install > Removal
Removal
Note
Removal and installation of the main headlights are identical on both sides; the procedure below refers only to one
of the headlights.
Remove front bumper Body - External assembly work; Rep. gr.63.
Remove the fastening screws -arrows-.
Pull the headlight carefully forward, disconnect the

multi-pin connector and remove the headlight by
moving it forward.
Vehicle electrics
Vehicle electrics
>
Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Main headlights (?07/06) - remove and install > Removal
>
Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Main headlights (?07/06) - remove and install > Installation
Installation
Tighten the fastening screws -arrows- in the order
indicated below: lower fastening screw to 3.5 Nm,
side fastening screw to 3.5 Nm, upper fastening
screw to 4 Nm.
Check the headlight assembly position for uniformity
of the clearance dimension. If the clearance between
the headlight and the body is not uniform, correct
the assembly position Chapter.
Note
After installing, the headlights must be adjusted
Chapter.
Vehicle electrics
Vehicle electrics
>
Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Main headlights (?07/06) - remove and install > Installation
>
Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Main headlights (?07/06) - correct the assembly position
Main headlights (07/06) - correct the assembly position
Note
Correcting the assembly position of the headlight lamps is identical on both sides; the procedure below refers only
to one of the headlights.
If the assembly position inspection indicates that the headlight clearance dimension in relation to the body is not
even, correct, then, the assembly position.

Loosen the fastening screws -arrows- for the
headlight.
Align, in relation to the body, moving the headlight
to the corresponding position.
Tighten the fastening screws -arrows- in the order
indicated below: lower fastening screw to 3.5 Nm,
side fastening screw to 3.5 Nm, upper fastening
screw to 4 Nm.
Check the headlight assembly position for clearance
uniformity. If necessary, correct.
Assemble the front bumper General body repairs,
exterior; Rep. gr.63.
Check the headlight operation.
Note
If the headlight is removed or adjusted in relation to
the body, it is always necessary to check the headlight
adjustment and carry out the adjustment on the
headlights.
Check and carry out the headlight adjustment
Chapter.
Vehicle electrics
>
Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Main headlights (?07/06) - correct the assembly position
Vehicle electrics Electrical system Lights, lamps, switches outside Main headlights (?07/06) > Left headlight beam reach control motor V48 and/or Right
headlight beam reach control motorV49 (Manufacturer - automotiv lighti
>
>
>
Left headlight beam reach control motor -V48- and/or Right headlight beam reach control motor -V49(Manufacturer - automotiv lighting) - remove and install .
t Electric adhesive cutter - glued glasses -VAG 1561At Knife -V.A.G 1561/18To replace the control motor, a repair set for the
control motor lid is necessary, in addition to the
control motor. This repair set has the following parts:
Two screws -1- for fastening the headlight reach

control motor.
t Rubber sealing ring -2-.
Four screws-3 - for fastening the headlight reach

control motor lid.
t Headlight reach control motor lid -4- .
Note
The removal and installation of the Left headlight
beam reach control motor -V48- and/or Right
t
headlight beam reach control motor -V49- can only
be performed with headlight removed.
If the control motors are removed, installed or
replace, an adjustment of the headlight base must
t always be performed with the adjusting device. The
tilting dimension is engraved in the headlight
housing.
In headlights from the manufacturer AL
t (Automotiv Lighting), the headlight compartment
must be sawed to replace the control motor.
t
Replacement of control motors is identical on both

sides; the procedure below refers only to one side.
headlight beam reach control motorV49 (Manufacturer - automotiv lighti
>
>
>
Vehicle electrics Electrical system Lights, lamps, switches outside Main headlights (?07/06) Left headlight beam reach control motor V48 and/or Right
head light beam reach control motorV49 (Manufacturer - automotiv lighti > Removal
>
>
>
>
Removal
Remove the main headlight Chapter.
Make sure that the headlight is manufactured by AL.
Lay the headlight with the plastic cover facing down in a clean and smooth base, because, if there is no protection
for the headlight cover, it may be easily scratched.
Install in the Electric adhesive cutter - glued glasses -VAG 1561A- the Knife -V.A.G 1561/18-.
Cut the headlight control motor lid near the lower

corner -arrow-.
Grind the sawed corner and remove the residues
from the headlight compartment sawing process.
Remove the cover and remove the connector from

the control motor -arrow-.
headlight beam reach control motorV49 (Manufacturer - automotiv lighti > Removal
>
>
>
>
headlight beam reach control motorV49 (Manufacturer - automotiv lighti > Installation
>
Installation
>
>
>
Install the new control motor with the screws arrows- in the new lid compartment from the repair
set.
Install the rubber sealing ring from the repair set in

the headlight compartment fitting -arrow-.
Install the control motor connector.
Pull the reflector upward, through the low beam

lamp opening, and hold it in this position.
Insert the ball head of the control motor -arrow- in

the reflector fitting.
Install the lid with the control motor installed in the

headlight compartment -arrows-.
Install the main headlight Chapter.
Note
Chapter.
Vehicle electrics Electrical system Lights, lamps, switches outside Main headlights (?07/06)
headlight beam reach control motorV49 (Manufacturer - automotiv lighti > Installation
>
>
>
>
Left headlight beam reach control motor V48 and/or Right
headlight beam reach control motorV49 (Manufacturer - Valeo) - remove
>
>
>
Left headlight beam reach control motor -V48- and/or Right headlight beam reach control motor -V49(Manufacturer - Valeo) - remove and install.
headlight beam reach control motorV49 (Manufacturer - Valeo) - remove > Removal
>
>
>
>
Removal
Note
t
If the control motors are removed, installed or replace, an adjustment of the headlight base must always be
performed with the adjusting device. The tilting dimension is engraved in the headlight housing.
t Replacement of control motors is identical on both sides; the procedure below refers only to one side.
Remove the headlight cover lid -arrow- .
Turn the adjustment motor -2- in the direction of

movement -seta- to the stop, and slightly remove it
from its fit -1-.
Displace the adjustment motor -3- in order to allow

removal of the ball head -2- in the direction of the arrow- from its fit -1-.
Pull the adjustment motor out of the headlight body,

observing cable clearance.
Disconnect the connector -1- for the adjustment

motor -2-.
headlight beam reach control motorV49 (Manufacturer - Valeo) - remove > Removal
>
>
>
>
headlight beam reach control motorV49 (Manufacturer - Valeo) - remove > Installation
>
>
>
>
Installation
Connect the connector -1- for the adjustment motor

-2-.
Carefully install the ball head for the adjustment

motor -2- in the direction of the -arrow- in its guide 1-.
Mount the headlight protection cover.

Check the headlight operation.
Note
Chapter.
Vehicle electrics Electrical system Lights, lamps, switches outside Main headlights (?07/06)
headlight beam reach control motorV49 (Manufacturer - Valeo) - remove > Installation
>
>
>
Vehicle electrics
>
>
Left headlight beam reach control mo tor V48 and/or Right
Free virus rem oval
Direc
Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Mains headlight lamps (?07/06) - replace
Mains headlight lamps (07/06) - replace
Note
t
Never touch the glass envelope when installing a lamp. The fingers leave traces of fat on the glass envelope, which
evaporate when the lamp is turned on, causing the glass to cloud over.
Replacement of the main headlight lamps is identical on both sides; the procedure below refers only to one of the
headlights.
Vehicle electrics > Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Mains headlight lamps (?07/06) - replace > Left front sidelight
lampM1 and/or Right front sidelight lampM3 - replace
Left front sidelight lamp -M1- and/or Right front sidelight lamp -M3- - replace
Remove the protection cover on the rear section of the headlight support.
Remove the socket with the lamp from the reflector

connector -arrow-.
After replacing the lamp, press the support with the
lamp toward inside the reflector, up to the stop.
Place the cover on the rear section of the headlight
support.
After installation, check the light functioning.
Chapter.
Vehicle electrics > Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Mains headlight lamps (?07/06) - replace > Left front sidelight
lampM1 and/or Right front sidelight lampM3 - replac
Vehicle electrics > Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Mains headlight lamps (?07/06) - replace > Left low-beam
headlight lampM29 and/or Right low-beam headlight lampM31 - replace
Left low-beam headlight lamp -M29- and/or Right low-beam headlight lamp -M31- - replace
Remove the protection cover on the rear section of the headlight support.
Remove the connector -1- from the lamp.
Release the locking ring -2- by turning it to the left.
Remove the lamp from the reflector.
Place the new lamp so that the fitting projections
are on the blade disc, located in the reflector cut.
Lock the locking ring -2- by turning it to the right.
Fit the connector -1-.
Install the cover on the rear section of the headlight
support.
After installing a new lamp, check the headlight
operation.
Chapter.
Vehicle electrics > Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Mains headlight lamps (?07/06) - replace > Left low-beam
headlight lampM29 and/or Right low-beam headlight lampM31 - replace
Vehicle electrics > Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Mains headlight lamps (?07/06) - replace > Left high-beam
headlight lampM30 and/or Right high-beam headlight lampM32 - replace
Left high-beam headlight lamp -M30- and/or Right high-beam headlight lamp -M32- - replace
Remove the cover on the rear section of the headlight support.
Disconnect the connector -1- from the lamp.
Press the locking ring -2- over the retaining
projections -3- and unlock.
Remove the lamp -4- from the reflector.
Place the new lamp so that the fitting projections
are on the blade disc located in the reflector cut.
Press the locking ring -2- over the retaining
projections -3- and lock.
Fit the connector -1-.
Place the cover.
Chapter.
Vehicle electrics > Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Mains headlight lamps (?07/06) - replace > Left high-beam
headlight lampM30 and/or Right high-beam headlight lampM32 - replace
Vehicle electrics
>
Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Mains headlight lamps (?07/06) - replace > Left front indicator
light lampM5 and/or Right front indicator light lampM7 - replace
Left front indicator light lamp -M5- and/or Right front indicator light lamp -M7- - replace
Remove the socket in the handle -arrow- and

remove the lamp.
Vehicle electrics
>
Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Mains headlight lamps (?07/06) - replace > Left front indicator
light lampM5 and/or Right front indicator light lampM7 - replace
Vehicle electrics
>
Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Main headlights (?07/06) - repair fastening tabs
Main headlights (07/06) - repair fastening tabs

If the upper headlight fastening tab -2-, the internal
lower headlight fastening tab -3-, or the side headlight
fastening tab -1- are damaged, they can be replaced
through the assembly of the repair set. It is not
necessary to replace the entire headlight.
Note
t
This condition depends entirely on the country

where the vehicle is commercialized.
If the upper headlight fastening fittings break due to

an external effort, there will be the possibility of
t repairing them at a reduced cost. The prior condition
is for the headlight compartment to not be
damaged.
The replacement of fastening tabs protections is
t identical on both sides; the procedure below refers
only to one side.
Vehicle electrics
>
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Special tools and workshop equipment required

t Torque Wrench - 4 to 20 Nm ( enc. 3/8") -VAG 1410-

"Torque wrench - 5 to 50 Nm (enc. 1/2")" -VAG

Battery -A- - disconnect and connect

Disconnect the Battery -A- (Version 1).

Release the fuse holder -1- by pressing the lock -2- in

Loosen the securing nut -1- on the negative terminal

Connect the Battery -A- (Version 1).

Fasten the positive terminal -4- to the positive pole

Fasten the negative terminal -2- to the negative pole

Lower the fuse holder -1- in the direction of - arrows

Connect the Battery -A- pole terminals manually and

Upon reconnecting the Battery -A-, check the vehicle

Disconnect the Battery -A- (Version 2).

Move the fuse holder to the side up to the limit of

Loosen the securing nut -1- on the negative terminal

Connect the Battery -A- (Version 2).

Fasten the positive terminal -4- to the positive pole

Fasten the negative terminal -2- to the negative pole

Insert the safety tabs in the housings -arrows- of the

Connect the Battery -A- pole terminals manually and

Upon reconnecting the Battery -A-, check the vehicle

instructions for use.

Disconnect the Battery -A- (Versions 3 and 4).

Loosen the securing nut -1- on the negative terminal

Unlock the positive pole cover of the Battery -A- and

Release the securing nut -2- and remove the cable

Connect the Battery -A- (Versions 3 and 4).

Fasten the positive terminal -4- to the positive pole

Fasten the negative terminal -2- to the negative pole

Connect the Battery -A- pole terminals manually and

Upon reconnecting the Battery -A-, check the vehicle

Disconnect the Battery -A- (Version 5).

Loosen securing nut -arrow- and remove earth wire

Press locks -arrows- and tilt the positive battery pole

Loosen securing nut -1- from positive wire -2-.

Connect the Battery -A- (Version 5).

Fit the earth wire terminal to the negative pole

t The Battery -A- terminals should not be lubricated.

Connect the Battery -A- pole terminals manually and

Upon reconnecting the Battery -A-, check the vehicle

Battery -A- - remove and install

Remove the Battery -A- (Version 1).

Loosen fastening bolt -1- of the Battery -A-tray.

Install the Battery -A- (Version 1).

Install the Battery -A- so that the base frame fits

The Battery -A- is properly installed when the central

In Batteries -A- without flexible tube for central

Connect the Battery -A- Chapter.

Remove the Battery -A- (Version 2).

Loosen fastening bolt -1- of the Battery -A-tray.

Install the Battery -A- (Version 2).

Install the Battery -A- so that the Battery -A- base

The Battery -A- is properly installed when the central

Install the fastening support -2- and tighten the

Connect Battery -A- Chapter.

Remove the Battery -A- (Version 3).

Disconnect the Battery -A- Chapter.

Remove the thermal protection from the Battery -A.

Loosen fastening bolt -1- of the Battery -A-tray.

Install the Battery -A- (Version 3).

Install the Battery -A- so that the Battery -A- base