Rear Lights. Volkswagen Touareg: Rear Lights

Transcription

1 Volkswagen Touareg: Rear Lights Page 1 / Rear Lights General information Rear light arrays containing parking, turn signal, and brake lights are located in each rear fender side panel. An additional rear light array located in the rear lid contains parking and back-up lights. Note: Additional information: Owners Manual Self Study Program - Course Number 89E303 "The Touareg" Self Study Program - Course Number 89J303 "The Touareg Electrical System Design and Function" Wiring Diagrams Component Locations On Board Diagnostic, function Rear light functions are monitored by Vehicle Electrical System Control Module J519 and Comfort System Central Control Module J393 which have On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory. In addition, the Troubleshoot rear light system malfunctions by performing OBD program using VAS 5051/5052 Tester in operating mode "Guided Fault Finding". Rear lights in rear fender side panel, assembly

2 Page 2 / 17 - Tightening torques 94-13, Rear lights in rear fender side panel, tightening torques 1 - Connection For rear lights in side panel. 2 - Bulb holder Removing and 94-5, Rear lights in rear fender side panel - bulb holder, removing and 3 - Left Rear Turn Signal Lamp M6 and Right Rear Turn Signal Lamp M8 12 V / PY 21 W Bulbs, replacing 94-5, Rear lights in rear fender side panel - bulb holder, removing and

3 Page 3 / 17 Checking 97-5, Vehicle Electrical System Control Module J519, Output Diagnostic Test Mode (DTM) 4 - Left Brake/Taillamp M21 and Right Brake/Taillamp M22 12 V / P 21 W / 4 W Bulbs, replacing 94-5, Rear lights in rear fender side panel - bulb holder, removing and Checking 97-5, Comfort System Central Control Module J393, Output Diagnostic Test Mode (DTM) 5 - Cover 6 - Screws For rear lights in side panel. 7 - Lock nuts 8 - Rear light housing Removing and 94-5, Rear light housing in rear fender side panels, removing and Body gaps/alignment specifications 94-5, Rear lights - body gaps/alignment Adjusting gaps 94-5, Rear light housing in side panel - body gaps/alignment, adjusting 9 - Ball head 10 - Plastic clip nut Replace for every removal of the rear light assembly 11 - Retaining plate Installing adjustable rear light assembly carrier 94-5,

4 Page 4 / 17 Adjustable rear light retainer, Rear light housing in rear fender side panels, removing and Caution! Should rear light housing be difficult to remove by hand, the Special Hook 3370 can be used as an aid as described below. Removing: Caution! Switch off all electrical consumers. Switch off ignition and remove ignition key. - Remove screw head covers - arrows -. - Remove screws - arrows -. Note: In addition to the screws, the rear light housing is

5 Page 5 / 17 secured by a ball head in a securing clip. If during the check of the final installation position it is established that the rear light housing body gaps and alignment are uneven with the body or rear light housing in rear lid, an adjustable retainer with plastic clip nut can be installed. 94-5, Rear light housing in side panel - body gaps/alignment, adjusting. Caution! Rear light housing may be damaged. Do not pry or turn rear light housing excessively in direction of arrow 1 in illustration N , otherwise the rear light lens will break. Should rear light housing be difficult to remove by hand, the Special Hook 3370 can be used as an aid. - Remove rear light housing in two steps as illustrated. First pull inside of rear light housing out slightly - arrow 1 - until upper edge of housing is visible. Then, pull housing by hand in direction of - arrow 2 -.

6 Page 6 / 17 - Disengage harness connector - arrow - and disconnect it. Note: If rear light assembly cannot be removed by hand, proceed as follows: Special tools, testers and auxiliary items required Special Hook Cover bumper cover with standard adhesive tape below rear light assembly to protect the paint. - Guide Special Hook into gap under rear light assembly as depicted in the illustration.

7 Page 7 / 17 - Carefully slide Special Hook 3370 on to position depicted in the illustration. Note: Magnified area in the illustration makes it clear at which location the Special Hook 3370 must be positioned to pull out the taillamp assembly. - Using the hand on the T-handle of Special Hook 3370, pull rear light assembly toward rear. - Support the pulling motion by also pulling and supporting with free hand in upper area of rear light assembly - arrow A -. Caution! Wiring harness to rear lights may be damaged. Carefully remove rear light housing taking into account the length of the rear light wiring harness. - Disengage and disconnect electrical connections - arrows -.

8 Page 8 / 17 Installing: Install in reverse order of removal, noting the following: Note: Plastic clip nut must be replaced after each removal of the rear light assembly! - Reconnect electrical connection. - Insert rear lights housing into opening, pressing ball head into new plastic clip nut Position rear lights housing properly on body panel by hand, hold securely and then tighten screws. - Check gap dimension 94-5, Rear lights - body gaps/alignment. Rear lights in rear fender side panel - bulb holder, removing and Removing: Caution! Switch off all electrical consumers. Switch off ignition and remove ignition key. - Remove rear light assembly in side panel 94-5, Rear light housing in rear fender side panels, removing and.

9 Page 9 / 17 - Release retainers - arrows - and remove bulb holder Installing: Install in reverse order of removal. Rear light housing in side panel - body gaps/alignment, adjusting Note: In the event that, after repairing collision damage to the rear body or replacement of a rear light the specified body gaps alignment of the rear light cannot be achieved, an adjustable retainer with mounting clips must be installed. A rear body side panel with stamped recess for tail light bracket is not available for repairs. A specially developed adjustable rear light retainer must be installed additionally. Adjustable rear light retainer components, description: 1x - A - Base with plastic clip nut

10 Page 10 / 17 2x - B - 1mm spacer 2x - C - Spacers, 0.5 mm 1x - D - Threaded plate 1x - E - Socket-head screw 1x - F - Socket-head screw Adjustable rear light retainer, assembly 1 - Threaded plate (4.0 mm thick) 2 - Clip mount (1.2 mm thick) 3 - Plastic clip nut 4 - Body sheet metal 5 - Spacer (0.5 mm thick) 6 - Socket head screw 7 - Spacer (1.0 mm thick) Adjustable rear light retainer, Preparation:

11 Page 11 / 17 - Position a spacer over the center of mounting hole (use as template) and mark diameters - G - and - H-. - Drill holes to dimensions - G - = 8 mm and - H - = 22 mm using a center-bit. - Enlarge mounting hole with sheet metal drill so that - G - = 22 mm and - H - = 8 mm (matches marked areas). Perform anti-corrosion measures Additional Information, Body Collision Repairs - General Information. Adjustable rear light retainer, : - Position a base with plastic clip nut behind mounting hole in the same orientation. - Place spacers behind as deemed necessary, position threaded plate with threads against body panel and loosely install screws so that retainer can still be moved 94-5, Adjustable rear light retainer, assembly. - Center and torque screws according to value in table 94-13, Rear lights in rear fender side panel, tightening torques. - Install rear light assembly 94-5, Rear light housing in rear fender side panels, removing and. - Check gap dimensions 94-5, Rear lights - body gaps/alignment.

12 Page 12 / 17 - If required, remove rear light assembly again, reposition retainer or adjust using spacers. Note: If the adjustment range is insufficient, shorten plastic clip nut in area of overhang - x - to obtain a greater range of adjustment. Rear lights in rear lid, assembly

13 Page 13 / 17 - Tightening torques 94-13, Rear lights in rear lid, tightening torques 1 - Rear light housing Removing and 94-5, Rear light housing in rear lid, removing and Body gaps/alignment specifications 94-5, Rear lights - body gaps/alignment 2 - Left Back-Up Lamp M16 and Right Back-Up Lamp M17 Bulbs, replacing 94-5, Rear lights in rear fender side panel - bulb holder, removing and 12 V / H 21 W

14 Page 14 / 17 Checking 97-5, Comfort System Central Control Module J393, Output Diagnostic Test Mode (DTM) 3 - Left Taillight Lamp 2 M49 and Right Taillight Lamp 2 M50 Bulbs, replacing 94-5, Rear lights in rear fender side panel - bulb holder, removing and 12 V / P 21 W / 4 W Checking 97-5, Comfort System Central Control Module J393, Output Diagnostic Test Mode (DTM) 4 - Bulb holder Removing and 94-5, Rear lights in rear fender side panel - bulb holder, removing and 5 - Connector For rear light assembly in rear lid 6 - Nuts For rear light assembly in rear lid 7 - Not applicable to USA/CDN Rear light housing in rear lid, removing and Removing: Caution! Switch off all electrical consumers. Switch off ignition and remove ignition key. - Open rear lid.

15 Page 15 / 17 - Unclip cover and remove in direction of - arrow-. - Disconnect electrical connection - arrow -. - Remove nuts and remove rear light housing. Installing: Install in reverse order of removal, noting the following: - Reconnect electrical connection. - Bring housing for rear light assembly into correct position to the body by hand, hold firmly and then tighten nuts. - Torque nuts according to value in table 94-13, Rear lights in rear lid, tightening torques. - Ensure even body gaps between rear light housing and body, as well as gaps and alignment between rear light housing in rear lid and rear light housing side panel 94-5, Rear lights - body gaps/alignment. Rear lights in rear lid - bulb holder, removing and Removing: Caution!

16 Page 16 / 17 Switch off all electrical consumers. Switch off ignition and remove ignition key. - Open rear lid. - Unclip cover and remove in direction of - arrow-. - Disconnect electrical connection - arrow -. - Release retainer - arrow - and remove bulb holder Installing:

17 Page 17 / 17 Install in reverse order of removal. Rear lights - body gaps/alignment 1 - Gap dimension 4 mm +/- 0.5 mm 2 - Gap dimension 1.0 mm +/-0.2 mm 3 - Rear surface alignment* 0.5 mm +/- 0.5 mm * This specification pertains to the position of the rear facing surfaces of both rear light housings relative to one another. The rear facing surfaces of both rear light housings must be flush with each another within the specification given.