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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.
Vehicle electrics > Electrical system > Starter-current supply-CC > Battery
Vehicle electrics
>
Electrical system > Starter-current supply -CC > Battery > BatteryA - 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.
Vehicles with fuse holder fastened to the Battery -Aconsole base (version 4) Chapter.
Vehicles with fuse holder fastened to the Battery -Aconsole base (version 5) 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).
WARNING
To avoid accident risks, always disconnect first the terminal connected to the negative pole of the Battery -A-.
Turn off the ignition and all electrical equipment, and remove the key from ignition.
Vehicle electrics
Vehicle electrics
>
>
Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect > Disconnect the BatteryA (Version 1).
Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect > Connect the BatteryA (Version 1).
Caution
Please observe the notes on the Battery -A-terminal fastening screw General information; Rep. gr.27.
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.
>
Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect > Connect the BatteryA (Version 1).
Vehicle electrics
>
Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect > Disconnect the BatteryA (Version 2).
WARNING
To avoid accident risks, always disconnect first the terminal connected to the negative pole of the Battery -A-.
Turn off the ignition and all electrical equipment, and remove the key from ignition.
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-.
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect > Disconnect the BatteryA (Version 2).
Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect > Connect the BatteryA (Version 2).
Caution
Please observe the notes on the Battery -A-terminal fastening screw General information; Rep. gr.27.
Lowe the fuse holder -2- until it fits the locks -1-.
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.
Vehicle electrics
>
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Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect > Connect the BatteryA (Version 2).
Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect > Disconnect the BatteryA (Versions 3 and 4).
WARNING
To avoid accident risks, always disconnect first the terminal connected to the negative pole of the Battery -A-.
Turn off the ignition and all electrical equipment, and remove the key from ignition.
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).
Caution
Please observe the notes on the Battery -A-terminal fastening screw General information; Rep. gr.27.
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.
Vehicle electrics
>
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Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect > Connect the BatteryA (Versions 3 and 4).
Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect > Disconnect the BatteryA (Version 5).
WARNING
To avoid accident risks, always disconnect first the terminal connected to the negative pole of the Battery -A-.
Turn off the ignition and all electrical equipment, and remove the key from ignition.
Vehicle electrics
Vehicle electrics
>
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Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect > Disconnect the BatteryA (Version 5).
Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect > Connect the BatteryA (Version 5).
Caution
Please observe the notes on the Battery -A-terminal fastening screw General information; Rep. gr.27.
Fit the positive wire terminal to the positive Battery -A- pole and tighten the fastening screw with the indicated
tightening torque Chapter.
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
Vehicle electrics
>
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Electrical system > Starter-current supply -CC > Battery > BatteryA - disconnect and connect > Connect the BatteryA (Version 5).
Electrical system > Starter-current supply -CC > Battery > BatteryA - 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).
Vehicle electrics
>
Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Remove the BatteryA (Version 1).
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Install the BatteryA (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-.
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Install the BatteryA (Version 1).
Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Remove the BatteryA (Version 2).
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Remove the BatteryA (Version 2).
Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Install the BatteryA (Version 2).
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-.
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Install the BatteryA (Version 2).
Vehicle electrics
>
Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Remove the BatteryA (Version 3).
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Remove the BatteryA (Version 3).
Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Install the BatteryA (Version 3).
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 fuse holder support claws to the Battery A-console, along with the respective terminals arrows-.
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Install the BatteryA (Version 3).
Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Remove the BatteryA (Version 4).
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Remove the BatteryA (Version 4).
Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Install the BatteryA (Version 4).
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 fuse holder support claws to the Battery A-console, along with the respective terminals arrows-.
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Install the BatteryA (Version 4).
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Remove the BatteryA (Version 5).
Release locks -arrows- and remove fuse carrier -1from Battery -A-console-2-.
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Remove the BatteryA (Version 5).
Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Install the BatteryA (Version 5).
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-.
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.
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA - remove and install > Install the BatteryA (Version 5).
Electrical system > Starter-current supply -CC > Battery > BatteryA 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
Turn off the ignition and all electrical equipment, and remove the key from ignition.
Disconnect and remove Battery -A- Chapter.
Vehicle electrics
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
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Electrical system > Starter-current supply -CC > Battery > BatteryA console - remove and install > BatteryA console (version 2) - remove and install
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:
Installation is performed in reverse sequence to the
removal, considering the following:
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > BatteryA console - remove and install > BatteryA console (version 2) - remove and install
>
Electrical system > Starter-current supply -CC > Battery > Tightening torques - Battery
Location
Tightening torques
6 Nm
25 Nm
16 Nm
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Battery > Tightening torques - Battery
>
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
Battery -A- (interrupting the current).
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
Vehicle electrics
Vehicle electrics
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Electrical system > Starter-current supply -CC > Starter > StarterB - remove and install
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Electrical system > Starter-current supply -CC > Starter > StarterB - remove and install > StarterB for vehicles with 1.0l, 1.6l and 2.0l engines (ARA,
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.
Disconnect the Battery -A- Chapter.
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-.
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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,
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:
Turn off the ignition, all the electrical devices, and remove the key from ignition.
Disconnect the Battery -A- Chapter.
Remove the Battery -A-support.
Remove the lower engine noise insulation, if necessary General body repairs, exterior; Rep. gr.50.
Vehicle electrics
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)
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Electrical system > Starter-current supply -CC > Starter > StarterB - remove and install > StarterB for vehicles with 1.4l engine (BAY)
Loosen the securing nut -2- (15 Nm) and remove the
support -2-.
Loosen the lower fastening screw -arrow- for the
Starter -B-.
Remove 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 1.4l engine (BAY)
>
Electrical system > Starter-current supply -CC > Starter > StarterB - remove and install > StarterB for vehicles with 1.9l engine (ASY)
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
8 - Screw
q 6.4 Nm.
9 - Brush holder
10 - Coil (Polar case)
11 - Gearing pinion and armature assembly
q Remove and install Chapter.
12 - Drive bearing
13 - Screw
q Used to fasten the magnetic wrench.
3.75
Nm.
Vehicle electrics
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Electrical system > Starter-current supply -CC > Starter > StarterB - (Manufacturer Valeo) - disassemble and assemble > Magnetic switch - remove
and install
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:
Installation is performed in reverse sequence to the
removal.
>
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
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:
Note
Please be very careful with your fingers, as the
armature is strongly pulled by the magnets.
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.
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
8 - Armature
q Remove and install Chapter.
9 - Gearing pinion
q Remove and install (Fastened on armature shaft) Chapter.
10 - Armature
q Remove and install Chapter.
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
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Electrical system > Starter-current supply -CC > Starter > StarterB - (Manufacturer Bosch) - disassemble and assemble > Magnetic switch - remove
and install
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.
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
Note
Please be very careful with your fingers, as the
armature is strongly pulled by the magnets.
Note
Please be very careful with your fingers, as the
armature is strongly pulled by the magnets.
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.
Install the Starter -B- Chapter.
Vehicle electrics
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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
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.
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.
Vehicle electrics > Electrical system > Starter-current supply-CC > Starter > StarterB - (Manufacturer Bosch) - disassemble and assemble > Gearing pinion (Fastened
on armature shaft) - remove and install
Vehicle electrics > Electrical system > Starter-current supply-CC > Starter > StarterB - (Manufacturer Bosch) - disassemble and assemble > Gearing pinion (Fastened
on planetary shaft) - remove and install
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-.
Vehicle electrics > Electrical system > Starter-current supply-CC > Starter > StarterB - (Manufacturer Bosch) - disassemble and assemble > Gearing pinion (Fastened
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
Vehicle electrics
>
Electrical system > Starter-current supply -CC > Starter > Tightening torques - Starter
Tightening torques
Starter to transmission
M12
80 Nm
Starter to transmission
M10
40 Nm
Earth wire
M8
15 Nm
Cable support
M8
15 Nm
15 Nm
Vehicle electrics
>
Alternator
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.
Check Generator (Alternator) -C-: Manual "Current flow diagram", Troubleshooting in the Electrical System and
Installation Locations.
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.
Vehicle electrics
>
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
Vehicle electrics
Vehicle electrics
>
Electrical system > Instruments, GCI > Combined instrument > Locating defects and indicating faults
>
Electrical system > Instruments, GCI > Combined instrument > Combined instrumentK - replace
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 A- earth wire.
t Before removing the Combined instrument -K-, follow the notes and work instructions for troubleshooting.
t
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.
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.
Vehicle electrics
>
Electrical system > Instruments, GCI > Combined instrument > Combined instrumentK - replace
Vehicle electrics
>
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
Vehicle electrics
>
Electrical system > Instruments, GCI > 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
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 A- earth wire.
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.
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
WARNING
At the moment of removal of the 12 volt socket -U5from the instrument panel, observe the compression
of the harness of the panel.
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:
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
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 A- earth wire.
t Safe working conditions for repairing the electrical system are created by disconnecting the earth wire from the
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.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper system - assembly overview
q 5 Nm.
6 - Windscreen wiper mechanism
q Remove and install Chapter.
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
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
Vehicle electrics > Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper blade - remove and install > Windscreen wiper
blade - streamlined (version 1)
Vehicle electrics > Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper blade - remove and install > Windscreen wiper
blade - streamlined (version 1)
Vehicle electrics > Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper blade - remove and install > Windscreen wiper
blade - streamlined (version 2)
Press button -1- and pull the wiper blade support -3removing it in the direction of the -seta- wiper arm 2-movement.
Installation:
Installation is performed in reverse sequence to the
removal.
Vehicle electrics > Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper blade - remove and install > Windscreen wiper
blade - streamlined (version 2)
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper blade and arm set - remove and install
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.
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
>
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
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.
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 mechanism - remove and install
Installation
Vehicle electrics
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper mechanism - remove and install > Remova l
Removal
Turn off the ignition and all electrical equipment, and remove the key from ignition.
Disconnect the Battery -A- Chapter.
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.
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:
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
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper motorV - disassemble and assemble >
Disassembly
Disassembly
Turn off the ignition and all electrical equipment, and remove the key from ignition.
Disconnect the Battery -A- Chapter.
Remove the windscreen wiper mechanism Chapter.
Note
When removing the linkage bars, make sure that the
rubber joints from the ball articulation are not
damaged.
Vehicle electrics
>
Disassembly
Vehicle electrics
>
>
Windscreen wiper system > Windscreen wiper motorV - disassemble and assemble >
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.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Windscreen wiper motorV - disassemble and assemble >
Assembly
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > 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
>
>
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
and the upper corner of the water deflector cover
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
and the upper corner of the water deflector cover
must be of 20 + 10mm.
Vehicles (08/2006 ):
The distance -B- between the windscreen blade end
and the upper corner of the water deflector cover
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
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.
Special tools and workshop equipment required
t Adjustment device -3358B Adjust the resting position of the windscreen wiper
arms Chapter.
-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-.
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 torques
20 Nm
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
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.
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
Turn off the ignition and all electrical equipment, and remove the key from ignition.
Disconnect the Battery -A- Chapter.
Remove the rearview mirror General body repairs, interior; Rep. gr.68.
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
Installation is performed in reverse sequence to the removal, considering the following:
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 Wedge -3409-
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Rain sensor and sunlight penetration photosensorG397 - remove
and install
Vehicle electrics
and install
> Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Rain sensor and sunlight penetration photosensorG397 - remove
> Removal
Removal
Turn off the ignition and all electrical equipment, and remove the key from ignition.
Disconnect the Battery -A- Chapter.
Remove the rearview mirror General body repairs, interior; Rep. gr.68.
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
>
Electrical system > Windscreen wipe/wash system > Windscreen wiper system > Rain sensor and sunlight penetration photosensorG397 - remove
Installation
Installation is performed in reverse sequence to the removal, considering the following:
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
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 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.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen washer system > 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
q Remove and install Chapter.
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
Special tools and workshop equipment required
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
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
Turn off the ignition and all electrical equipment, and remove the key from ignition.
Disconnect the Battery -A- Chapter.
Remove the front bumper General body repairs, exterior; Rep. gr.63.
Disconnect the connector from the Windscreen washer pump -V5-.
Vehicle electrics
>
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 > Installation
Installation
Installation is performed in reverse sequence to the removal, considering the following:
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.
Vehicle electrics > Electrical system > Windscreen wipe/wash system > Windscreen washer system > Reservoir for the windscreen and rear window washer system
(version 2) - remove and install
Reservoir for the windscreen and rear window washer system (version 2) - remove and install
Vehicle electrics > Electrical system > Windscreen wipe/wash system > Windscreen washer system > Reservoir for the windscreen and rear window washer system
(version 2) - remove and install
Vehicle electrics
> Electrical system > Windscreen wipe/wash system > Windscreen washer system > Reservoir for the windscreen and rear window washer system
(version 2) - remove and install > Removal
Removal
Turn off the ignition and all electrical equipment, and remove the key from ignition.
Disconnect the Battery -A- Chapter.
Remove the front bumper General body repairs, exterior; Rep. gr.63.
Disconnect the connector from the Windscreen washer pump -V5-.
Vehicle electrics
> Electrical system > Windscreen wipe/wash system > Windscreen washer system > Reservoir for the windscreen and rear window washer system
(version 2) - remove and install > Installation
Installation
Installation is performed in reverse sequence to the removal, considering the following:
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.
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
>
Electrical system > Windscreen wipe/wash system > Windscreen washer system > Windscreen and rear window washer pumpV59 - remove and
> Removal
Removal
Turn off the ignition and all electrical equipment, and remove the key from ignition.
Disconnect the Battery -A- Chapter.
Remove the left wheel arch cover Body - External assembly works; Rep. gr.66.
Remove the connector and the hose connections in the pump.
Vehicle electrics
install
>
Electrical system > Windscreen wipe/wash system > Windscreen washer system > Windscreen and rear window washer pumpV59 - remove and
> Removal
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen washer system > Windscreen and rear window washer pumpV59 - remove and
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
Vehicle electrics
>
5 Nm
Electrical system > Windscreen wipe/wash system > Windscreen washer system > Windscreen washer system washer je ts - replace
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Windscreen washer system > Windscreen washer system washer jets - replace > Removal
Removal
Turn off the ignition and all electrical equipment, and remove the key from ignition.
Disconnect the Battery -A- Chapter.
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
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.
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
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 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.
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
1 - Protection cover
2 - Hexagonal nut
q 15 Nm.
3 - Rear window wiper arm
q Remove and install Chapter.
q Adjust Chapter.
4 - Sealing eyelet
q Replace if damaged.
5 - Washer jet
q Replace Chapter.
q Adjust Chapter.
6 - Sealing ring
q Replace if damaged.
7 - Rear window wiper motor -V12q Remove and install Chapter.
8 - Hexagonal nut
q 8 Nm.
9 - Rubber washer
q Replace if damaged.
10 - Spacer
11 - Rear window wiper blade
q Remove and install Chapter.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window wiper system > 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
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
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window wiper system > Rear window wiper motorV12 - remove and install > Removal
Removal
Turn off the ignition and all electrical equipment, and remove the key from ignition.
Disconnect the Battery -A- Chapter.
Remove rear window wiper arm Chapter.
Remove the rear lid lining General body repairs, interior; Rep. gr.70.
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.
Tighten the securing nuts to the specified torque Chapter.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window wiper system > Tightening torques - rear window wiper system
Tightening torques
8 Nm
12 Nm
Vehicle electrics
>
M8
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 resting position - adjust
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window wiper system > 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)
Press the lock -arrow- and pull the blade -1- in the
direction -arrow-, and remove it.
Installation:
Installation is performed in reverse sequence to the
removal.
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)
Vehicle electrics > Electrical system > Windscreen wipe/wash system > Rear window wiper system > Rear window wiper blade - remove and install > Rear window
wiper blade (version 2)
Vehicle electrics > Electrical system > Windscreen wipe/wash system > Rear window wiper system > Rear window wiper blade - remove and install > Rear window
wiper blade (version 2)
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window washer system
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.
The conditions for safe work on the electrical system are created by disconnecting the Battery -A- grounding cable
(interruption of 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.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window washer system > 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
q Remove and install Chapter.
Vehicle electrics
>
Electrical system > Windscreen wipe/wash system > Rear window washer system > 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
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.
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)
WARNING
Before executing any work on the electric system, it is necessary to disconnect the battery -A- Chapter earth
cable.
Note
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.
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
1 - Main headlight
q Remove and install Chapter.
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.
3 - Protection cover
4 - Left front indicator light lamp -M5- and/or Right front indicator light lamp -M7-
Vehicle electrics
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Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Main headlights (?07/06) - remove and install
Vehicle electrics
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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.
Turn off the ignition and all electrical equipment, and remove the key from ignition.
Disconnect the Battery -A- Chapter.
Remove front bumper Body - External assembly work; Rep. gr.63.
Vehicle electrics
Vehicle electrics
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Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Main headlights (?07/06) - remove and install > Removal
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Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Main headlights (?07/06) - remove and install > Installation
Installation
Installation is performed in reverse sequence to the removal, considering the following:
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
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Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Main headlights (?07/06) - remove and install > Installation
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Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > 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
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
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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
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Left headlight beam reach control motor -V48- and/or Right headlight beam reach control motor -V49(Manufacturer - automotiv lighting) - remove and install .
Special tools and workshop equipment required
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:
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
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
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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
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Removal
Turn off the ignition and all electrical equipment, and remove the key from ignition.
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-.
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 > Removal
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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 > Installation
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Installation
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Install the new control motor with the screws arrows- in the new lid compartment from the repair
set.
Note
After installing, the headlights must be adjusted
Chapter.
Vehicle electrics Electrical system Lights, lamps, switches outside Main headlights (?07/06)
headlight beam reach control motorV49 (Manufacturer - automotiv lighti > Installation
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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 - Valeo) - remove
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Left headlight beam reach control motor -V48- and/or Right headlight beam reach control motor -V49(Manufacturer - Valeo) - remove and install.
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 - Valeo) - remove > Removal
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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.
Turn off the ignition and all electrical equipment, and remove the key from ignition.
Disconnect the Battery -A- Chapter.
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 - Valeo) - remove > Removal
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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 - Valeo) - remove > Installation
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Installation
Installation is performed in reverse sequence to the removal, considering the following:
Note
After installing, the headlights must be adjusted
Chapter.
Vehicle electrics Electrical system Lights, lamps, switches outside Main headlights (?07/06)
headlight beam reach control motorV49 (Manufacturer - Valeo) - remove > Installation
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Vehicle electrics
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Direc
Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > 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
Turn off the ignition and all electrical equipment, and remove the key from ignition.
Disconnect the Battery -A- Chapter.
Remove the protection cover on the rear section of the headlight support.
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
Turn off the ignition and all electrical equipment, and remove the key from ignition.
Disconnect the Battery -A- Chapter.
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.
Check and carry out the headlight adjustment
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
Turn off the ignition and all electrical equipment, and remove the key from ignition.
Disconnect the Battery -A- Chapter.
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.
After installation, check the light functioning.
Check and carry out the headlight adjustment
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
Left front indicator light lamp -M5- and/or Right front indicator light lamp -M7- - replace
Turn off the ignition and all electrical equipment, and remove the key from ignition.
Disconnect the Battery -A- Chapter.
Vehicle electrics
>
Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Mains headlight lamps (?07/06) - replace > Left front indicator
Vehicle electrics
>
Electrical system > Lights, lamps, switches outside > Main headlights (?07/06) > Main headlights (?07/06) - repair fastening tabs
Note
t
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