Windshield Wiper System

Transcription

1 Volkswagen Golf 5 - Windshield Wiper System Volkswagen Technical Site: Page 1 / Windshield Wiper System General information The windshield wiper system is controlled by the Wiper Motor Control Module J400 which is integrated with Windshield Wiper Motor V. To remove wiper blades, wiper arms must be set to "service/winter position". The "service/winter position" is activated by operating windshield wiper lever in "touch sweep" position within 10 seconds after switching off ignition Owners Manual. Note: In order to prevent potential damage to wiper arms, the windshield wipers will not function, or will cease functioning should the front hood be opened. Additional information: Owners Manual Self Study Program - Course Number "VW 2006 GTI Introduction" Wiring Diagrams Component Locations Caution! When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications, as well as instructions on performing OBD program and electrical system function checks as specified in this Repair Manual 27-4, Battery, disconnecting and connecting.

2 Windshield Wiper System Page 2 / 15 On Board Diagnostic (OBD), functions Wiper Motor Control Module J400 and Vehicle Electrical System Control Module J519 have On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory. Troubleshoot windshield wiper malfunctions by performing OBD program using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding". Windshield wiper system, checking with Output Diagnostic Test Mode (DTM) Windshield wiper system operation can be checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module J Connect Vehicle Diagnostic, Testing and Information System VAS 5051/ , VAS 5051 / Select operating mode "Guided Fault Finding" - Enter information as prompted and press ">" to confirm. After the DTC memory of all control modules has been checked: - Use "Go to" button to select "Function / Component Selection" - Select "Body (Repair Group 01; 27; 50-97)" - Select "Electrical system int/ext (Repair Group 01; 27; 90-97)" - Select "01 - Self-diagnosis" - Select "Vehicle Electrical System Control Module" - Select "Vehicle Electrical System Control Module functions" - Select "J519 - output DTM, sequential (Repair Group 97)" - Press ">" to confirm. - Select "1 - Output Diagnostic Test Mode (DTM) for an individual component" - Select "Another actuator" until selection for "Wiper" is displayed

3 Windshield Wiper System Page 3 / 15 - Follow tester prompts Windshield wiper - Alternating Park Position (APP) function, deactivating Special tools, testers and auxiliary items required Vehicle Diagnostic, Testing and Information System VAS 5051/5052 (VAS 5051 A version shown as example only) Diagnostic cable VAS 5051/6A (or length appropriate alternative) Windshield wiper system is equipped with Alternating Park Position (APP) function). Every other time the wipers are witched off, the APP function causes the wiper arms to move upward slightly from the lowest position, causing the wiper blade rubbers to "flip" or tilt in a manner that "alternates" from the previous switch-off event. APP function serves to increase wiper blade service life by alternating the wiper rubber contact angle at the windshield after use.

4 Windshield Wiper System Page 4 / 15 In order to install the crank on the wiper motor in the proper position, it is necessary to shut off the motor in the lowest park position. This is done by deactivating the APP function in the coding of Wiper Motor Control Module J400. Note: Activating APP function is not possible. APP function is automatically activated after 100 wiping cycles. This applies to wiper motors in which the APP function was deactivated as well as for new wiper motors. - Connect Vehicle Diagnostic, Testing and Information System VAS 5051/ , VAS 5051 / Select operating mode "Guided Fault Finding" - Enter information as prompted and press ">" to confirm. After the DTC memory of all control modules has been checked: - Use "Go to" button to select "Function / Component Selection" - Select "Body (Repair Group 01; 27; 50-97)" - Select "Electrical system int/ext (Repair Group 01; 27; 90-97)" - Select "01 - Self-diagnosis" - Select "Vehicle Electrical System Control Module" - Select "Vehicle Electrical System Control Module functions" - Select "Coding control module for wiper electronics/deactivating APP" - Press ">" to confirm. - Follow tester prompts Windshield wiper assembly, removing and installing Caution! When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications as well as instructions on performing

5 Windshield Wiper System Page 5 / 15 OBD program and electrical system function checks as specified in this Repair Manual 27-4, Battery, disconnecting and connecting. Special tools, testers and auxiliary items required Torque wrench VAG 1331 (or equivalent 5-50 Nm) Pry lever Windshield wiper system, removing - preparation - Deactivate APP function 92-1, Windshield wiper - Alternating Park Position (APP) function, deactivating. - Operate wipers briefly and allow to move to park position. Switch off ignition. - Disconnect battery 27-4, Battery, disconnecting and connecting. Note: In order to be able to remove wiper frames with linkages and wiper motor, wiper arms plenum chamber cover, and air guide trim must be removed.

6 Windshield Wiper System Page 6 / 15 Wiper arms, removing - Pry off caps - arrows - from wiper arms. - Loosen nuts - arrows - (do not remove). - Lift wiper arm and loosen by gently rocking back and forth on shaft until felt to release. - Remove nut and wiper arm. Plenum chamber cover, removing Plenum chamber cover, removing and installing. Repair Manual, Body Exterior, Repair Group 64, Plenum chamber bulkhead trim, removing

7 Windshield Wiper System Page 7 / 15 - Remove screw and nut from trim Remove trim upward and from vehicle. Wiper assembly, removing - Disconnect electrical connection Remove screws - arrows - and swing wiper arms upward and from vehicle. Wiper motor, removing from frame - Pry off ball head - arrow - of linkage from motor crank using pry lever

8 Windshield Wiper System Page 8 / 15 - Remove nut Remove motor crank from wiper motor shaft. - Remove screws - arrows - and remove wiper motor with control module from wiper frame. Wiper motor, installing in frame - Insert wiper motor with control module into frame and secure with screws - arrows -. - Tighten all fasteners according to values in table 92-8, Wiper and Washer Systems, tightening torques. - Place motor crank onto wiper motor shaft. Distance

9 Windshield Wiper System Page 9 / 15 - a - to stop must be 3 1 mm. - Install crank to wiper motor shaft using nut Tighten all fasteners according to values in table 92-8, Wiper and Washer Systems, tightening torques. - Press ball head - arrow - of linkage - 1-onto crank. Windshield wiper assembly, installing - Install wiper frame in reverse sequence. While installing, securing pin of wiper frame must be inserted into grommet on bulkhead. - Tighten all fasteners according to values in table 92-8, Wiper and Washer Systems, tightening torques. - Connect electrical connection to wiper motor connection and engage it. - Install air duct trim in reversed sequence. - Install plenum chamber cover Repair Manual, Body Exterior, Repair Group 64, Gravity bonded windows; Plenum chamber cover, assembly

10 Windshield Wiper System Page 10 / 15 overview. - Reconnect battery 27-4, Battery, disconnecting and connecting. - Install wiper arms 92-1, Wiper arms, removing and installing. Wiper arms, removing and installing Removing: - Wiper arms, removing 92-1, Wiper arms, removing. Installing: Note: Wiper arm nuts must only be torqued after wiper blade park position is checked and adjusted. - Deactivate APP function 92-1, Windshield wiper - Alternating Park Position (APP) function, deactivating if not already done by this time. - Operate wipers briefly, allow to run to park position and then switch off ignition. - Mount wiper arms to wiper shaft and loosely install nuts - arrows - (do not tighten). - Adjust wiper blade park position 92-1, Wiper blade park position, checking and adjusting. Wiper blade park position, checking and adjusting Special tools, testers and auxiliary items required

11 Windshield Wiper System Page 11 / 15 Torque wrench VAG 1331 (or equivalent 5-50 Nm) - Deactivate APP function 92-1, Windshield wiper - Alternating Park Position (APP) function, deactivating if not already done by this time. - Operate wipers briefly, allow to run to park position and then switch off ignition. - If necessary, loosen wiper arm nut and adjust wiper blade park position as illustrated below: Drivers side: Distance - A - between tips of wiper lips and upper edge of cowl panel must be 10 mm. - If necessary, set end position of windshield wiper blades by offsetting wiper arms. Wiper arms, removing 92-1, Wiper arms, removing. - Tighten all fasteners according to values in table 92-8, Wiper and Washer Systems, tightening torques.

12 Windshield Wiper System Page 12 / 15 Passengers side: Distance - B - between tips of wiper lips and upper edge of cowl panel must be 10 mm. - If necessary, set end position of windshield wiper blades by offsetting wiper arms. Removing wiper arms 92-1, Wiper arms, removing. Wiper arms, removing 92-1, Wiper arms, removing. - Tighten all fasteners according to values in table 92-8, Wiper and Washer Systems, tightening torques. "Aero-wiper" blades, removing and installing Removing: Note: Driver and passenger wiper blades are different lengths. Damage will result if wiper blades are interchanged. To ensure proper wiper performance, only grab/lift Aero-wiper blades at the mounting pivot on wiper arm when removing and installing. To remove wiper blades, wiper arms must be set to "service/winter position". The "service/winter position" is activated by operating windshield wiper lever in "touch sweep" position within 10 seconds after switching off ignition. - Set wiper arms to "service/winter position" by operating windshield wiper lever in "touch sweep" position within 10 seconds after switching off ignition.

13 Windshield Wiper System Page 13 / 15 - Fold wiper arm away from windshield. - Turn wiper blade on wiper arm until it reaches stop - arrow A -. - Pull off wiper blade from wiper arm pivot - arrow B -. Installing: - Slide wiper blade onto axle of wiper arm. - Turn wiper blade on wiper arm axle until it reaches stop. - Carefully fold wiper arm back onto windshield. Rain/Light Recognition Sensor G397, removing and installing In the event a Rain/Light Recognition Sensor G397 is bale to be removed intact from the bracket (for example, upon windshield replacement), it can be reinstalled. Ensure sensor is stored free from dust and debris, and that the contact pads are not damaged. Special tools, testers and auxiliary items required Trim removal wedge 3409

14 Windshield Wiper System Page 14 / 15 Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove interior mirror Repair Manual, Body Interior, Repair Group 68, removing and installing interior mirror. - Disconnect electrical connection from Rain/Lamp Recognition Sensor G Using trim removal wedge 3409, pry Rain/Lamp Recognition Sensor G from bracket Note: While removing, the complete Rain/Lamp Recognition Sensor G397 and not only the upper

15 Windshield Wiper System Page 15 / 15 shell of the sensor must be pried off. Installing: Install in reverse order of removal, noting the following: Note: Always clean windshield surface inside bracket for Rain/Lamp Recognition Sensor G397 before installing. Surface (connecting pads) of Rain/Lamp Recognition Sensor G397 must not be soiled when installing. If the surface (connecting pads) of Rain/Lamp Recognition Sensor G397 is soiled, it can be potentially cleaned by "applying" and then "pulling off" one or more adhesive strips. After installing Rain/Lamp Recognition Sensor G397, there must be no air bubbles between windshield and surface (connecting pads).

16 Volkswagen Golf 5 - Windshield Washer System Page 1 / 13 Volkswagen Technical Site: Windshield Washer System General information Note: Additional information: Owners Manual Wiring Diagrams Component Locations Caution! When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications as well as instructions on performing OBD program and electrical system function checks as specified in this Repair Manual 27-4, Battery, disconnecting and connecting. On Board Diagnostic (OBD), functions Windshield washer functions are controlled by the Vehicle Electrical System Control Module J519 which has On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory. Troubleshoot windshield washer malfunctions by performing OBD program using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding". Windshield washer system, checking with Output Diagnostic Test Mode (DTM) Windshield washer system operation can be checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module J Connect Vehicle Diagnostic, Testing and Information System VAS 5051/ , VAS 5051 / Select operating mode "Guided Fault Finding" - Enter information as prompted and press ">" to confirm. After the DTC memory of all control modules has been checked:

17 Windshield Washer System Page 2 / 13 - Use "Go to" button to select "Function / Component Selection" - Select "Body (Repair Group 01; 27; 50-97)" - Select "Electrical system int/ext (Repair Group 01; 27; 90-97)" - Select "01 - Self-diagnosis" - Select "Vehicle Electrical System Control Module" - Select "Vehicle Electrical System Control Module functions" - Select "J519 - output DTM, sequential (Repair Group 97)" - Select "1 - Output Diagnostic Test Mode (DTM) for an individual component" - Select "Another actuator" until selection for "Dual windshield washer pump" is displayed - Follow tester prompts Windshield washer system, component overview

18 Windshield Washer System Page 3 / 13 Y-piece Routes washer hoses to washer jets Right windshield washer jet Removing and installing 92-2, Windshield washer jets, removing and installing Adjusting 92-2, Windshield washer jets, checking and adjusting Left windshield washer jet Removing and installing 92-2, Windshield washer jets, removing and installing

19 Windshield Washer System Page 4 / 13 Adjusting 92-2, Windshield washer jets, checking and adjusting Angle coupling Washer hose coupling to left washer jet Overview 92-6, Washer Hose Couplings Washer hose Repairing 92-7, Washer Hose Repair Angle coupling Washer hose coupling to right washer jet Overview 92-6, Washer Hose Couplings Washer fluid reservoir filling tube Removing and installing 92-2, Washer fluid reservoir filling tube, removing and installing Washer fluid reservoir connecting tube removed and installed together with reservoir Washer fluid reservoir Removing and installing 92-2, Washer fluid reservoir, removing and installing Windshield and Rear Window Washer Pump V59 Removing and installing

20 Windshield Washer System Page 5 / , Windshield and Rear Window Washer Pump V59, removing and installing Angle coupling Connection to Windshield and Rear Window Washer Pump V59 Overview 92-6, Washer Hose Couplings Windshield Washer Fluid Level Sensor G33 Removing and installing 92-2, Windshield Washer Fluid Level Sensor G33, removing and installing Washer fluid reservoir, removing and installing Washer fluid reservoir is made of three parts connected together. In order to guarantee the correct position of the parts to each other, make sure that the guides present on the individual components engage in each other while assembling. 1 - Filling tube 2 - Connecting tube (removed and installed together with

21 Windshield Washer System Page 6 / 13 reservoir) 3 - Washer fluid reservoir Washer fluid reservoir filling tube, removing and installing Removing: - Pull off connecting tube from washer fluid reservoir filler tube Remove screw Unclip hose bracket from filling tube - 3-and remove. Installing: Install in reverse order of removal, noting the following: Locating pin on underside of filler tube must be inserted into hole - arrow -.

22 Windshield Washer System Page 7 / 13 Connecting tube and filling tube must be joined so that the guides - arrows - engage in each other. Washer fluid reservoir, removing and installing Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove filling tube 92-2, Washer fluid reservoir filling tube, removing and installing. - Remove front bumper cover Repair Manual, Body Exterior, Repair Group 63, Front bumper. Note: In order to prevent interchanging washer fluid line connections at Windshield and Rear Window Washer Pump V59, connections at pump and hose lines are color-coded. Hose connector pieces must be connected to the corresponding colored pump connections during installation.

23 Windshield Washer System Page 8 / 13 - To release, twist securing clips at hose connections and and disconnect from Windshield and Rear Window Washer Pump V If necessary, retain washer fluid using suitable container. - Disconnect electrical connection at sensor Pull Windshield and Rear Window Washer Pump V upward from reservoir and disconnect electrical connection Where applicable, pull Headlamp Washer Pump V upward from reservoir and disconnect electrical connection

24 Windshield Washer System Page 9 / 13 - Remove screws - arrows - and remove reservoir with filling tube and connector tube from vehicle. Installing: Install in reverse order of removal, noting the following: - Tighten all fasteners according to values in table 92-8, Wiper and Washer Systems, tightening torques. - Where applicable, bleed headlamp washer system after completing assembly work 92-5, Headlamp washer system, bleeding. Windshield and Rear Window Washer Pump V59, removing and installing Note: Depending on equipment, location of Windshield and Rear Window Washer Pump V59 may differ slightly from illustrations. Removal is similar. Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove front bumper cover Repair Manual, Body Exterior, Repair Group 63, Front bumper. Note: In order to prevent interchanging washer fluid line connections at Windshield and Rear Window Washer Pump V59, connections at pump and hose lines are color-coded. Hose connector pieces must be connected to the corresponding colored pump connections during installation.

25 Windshield Washer System Page 10 / 13 - To release, twist securing clips at hose connections and and disconnect from Windshield and Rear Window Washer Pump V If necessary, retain washer fluid using suitable container. - Remove Windshield and Rear Window Washer Pump V upward from reservoir. - Disconnect electrical connection Installing: Install in reverse order of removal, noting the following: - Tighten all fasteners according to values in table 92-8, Wiper and Washer Systems, tightening torques. - Where applicable, bleed headlamp washer system after completing assembly work 92-5, Headlamp washer system, bleeding. Windshield Washer Fluid Level Sensor G33, removing and installing Note: Depending on equipment, location of Windshield and Rear Window Washer Pump G33 may differ slightly from illustrations. Removal is similar. Removing: Caution!

26 Windshield Washer System Page 11 / 13 Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove front bumper cover Repair Manual, Body Exterior, Repair Group 63, Front bumper. - Disconnect electrical connection at sensor Pull Windshield Washer Fluid Level Sensor G out from rubber grommet. - If necessary, retain washer fluid using suitable container. Installing: Install in reverse order of removal, noting the following: - Where applicable, bleed headlamp washer system after completing assembly work 92-5, Headlamp washer system, bleeding. Windshield washer jets, removing and installing Removing:

27 Windshield Washer System Page 12 / 13 - Press nozzle upward - arrow A - and pull out flap at rear - arrow B -. - Disconnect hose from washer jet and disconnect electrical connection Installing: - Connect electrical connection and hose to washer jet. - Slide washer jet into installation opening until it engages audibly. - Check jets and adjust if necessary 92-2, Windshield washer jets, checking and adjusting. Windshield washer jets, checking and adjusting Note: In the event contamination in washer jet produces an uneven spray pattern, remove washer jet and rinse it with water in the opposite direction of spray. It is permissible to further blow through in opposite direction of spray with compressed air. Do not use solid objects to clean washer jets

28 Windshield Washer System Page 13 / 13 Repair Manual, Maintenance, Repair Group 00,

29 Volkswagen Golf 5 - Rear Window Wiper System Page 1 / Rear Window Wiper System General information Note: Additional information: Owners Manual Wiring Diagrams Component Locations Caution! When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications as well as instructions on performing OBD program and electrical system function checks as specified in this Repair Manual 27-4, Battery, disconnecting and connecting. On Board Diagnostic (OBD), functions Rear window wiper functions are controlled by the Vehicle Electrical System Control Module J519 which has On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory. Troubleshoot rear window wiper malfunctions by performing OBD program using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding". Rear window wiper system, checking with Output Diagnostic Test Mode (DTM) Rear window wiper system operation can be checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module J Connect Vehicle Diagnostic, Testing and Information System VAS 5051/ , VAS 5051 / Select operating mode "Guided Fault Finding" - Enter information as prompted and press ">" to confirm. After the DTC memory of all control modules has been checked:

30 Rear Window Wiper System Page 2 / 9 - Use "Go to" button to select "Function / Component Selection" - Select "Body (Repair Group 01; 27; 50-97)" - Select "Electrical system int/ext (Repair Group 01; 27; 90-97)" - Select "01 - Self-diagnosis" - Select "Vehicle Electrical System Control Module" - Select "Vehicle Electrical System Control Module functions" - Select "J519 - output DTM, sequential (Repair Group 97)" - Select "1 - Output Diagnostic Test Mode (DTM) for an individual component" - Select "Another actuator" until selection for "Rear window wiper" is displayed - Follow tester prompts Rear window wiper system, assembly overview

31 Rear Window Wiper System Page 3 / Cap 2 - Nut SW Nm 3 - Wiper arm Removing 92-3, Rear window wiper arm, removing Installing 92-3, Rear window wiper arm, installing Adjusting park position 92-3, Rear window wiper park position, checking and adjusting 4 - Gasket 5 - Rear window washer jet Removing and installing 92-4,

32 Rear Window Wiper System Page 4 / 9 Rear window washer jet, removing and installing Checking and adjusting 92-4, Rear window washer jet, checking and adjusting 6 - Sealing ring 7 - Rear Window Wiper Motor V12 Removing and installing 92-3, Rear Window Wiper Motor V12, removing and installing 8 - M6 nut with washer 8 Nm 9 - Rubber ring 10 - Spacer 11 - "Aero-wiper" blade Removing and installing 92-3, Aero-wiper blade, removing and installing Rear window wiper assembly, removing and installing Special tools, testers and auxiliary items required Torque wrench VAG 1331 (or equivalent 5-50 Nm) Rear window wiper arm, removing - Switch ignition on and momentarily activate rear wiper in order to ensure wiper returns to park position.

33 Rear Window Wiper System Page 5 / 9 Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Fold back cap and unclip from wiper arm. - Loosen nut - arrow - (do not remove). Caution! Aero-wipers are very flexible. Grasp wiper blades only in area of wiper blade mount to lift them from rear window. - Lift wiper arm and loosen by gently rocking back and forth on shaft until felt to release. - Remove nut - arrow - and remove wiper arm. Rear Window Wiper Motor V12, removing and installing Removing: - Remove rear window wiper arm 92-3, Rear window wiper arm, removing - Disconnect battery 27-4, Battery, disconnecting and connecting. - Remove rear lid trim Repair Manual, Body - Interior, Repair Group 70, Rear lid trim.

34 Rear Window Wiper System Page 6 / 9 - Release and disconnect electrical connection Release and disconnect hose coupling by pulling up on securing ring, and remove hose from motor. - Remove nuts - arrows -. - Remove motor from rear lid. Installing: Install in reverse order of removal, noting the following: - Ensure correct fitting and orientation of gasket. Position mark on gasket must align with mark in rear window. - Reconnect battery 27-4, Battery, disconnecting and connecting. Rear window wiper arm, installing - Switch ignition on and momentarily activate rear wiper in order to ensure wiper motor returns to park position. Caution! Switch off all electrical consumers.

35 Rear Window Wiper System Page 7 / 9 Switch ignition off and remove ignition key. - Place wiper arm onto wiper shaft in the approximate park position and tighten nut - arrow - by hand. Note: Only tighten/torque nut - arrow - after adjusting rear window wiper park position. - Adjust rear window wiper park position 92-3, Rear window wiper park position, checking and adjusting. Rear window wiper park position, checking and adjusting Special tools, testers and auxiliary items required Torque wrench VAG 1331 (or equivalent 5-5- Nm)

36 Rear Window Wiper System Page 8 / 9 Gap dimension - a - between wiper blade and lower edge of rear window must be 23 mm. - If necessary, reset park position of rear window wiper by loosening arms 92-3, Rear window wiper arm, removing. - Tighten all fasteners according to values in table 92-8, Wiper and Washer Systems, tightening torques. "Aero-wiper" blade, removing and installing Caution! Aero-wipers are very flexible. Grasp wiper blades only in area of wiper blade mount to lift them from rear window. Removing: - Fold up wiper arm. - Release wiper blade mounting from wiper arm in direction of - arrow -.

37 Rear Window Wiper System Page 9 / 9 - Separate wiper blade from wiper arm -arrow-. Installing: Install in reverse order of removal, noting the following: - Engage wiper arm mounting fully onto wiper arm. - Carefully fold wiper arm/blade onto rear window.

38 Volkswagen Golf 5 - Rear Window Washer System Page 1 / Rear Window Washer System General information Note: Additional information: Owners Manual Wiring Diagrams Component Locations Caution! When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications as well as instructions on performing OBD program and electrical system function checks as specified in this Repair Manual 27-4, Battery, disconnecting and connecting. On Board Diagnostic (OBD), functions Rear window washer functions are controlled by the Vehicle Electrical System Control Module J519 which has On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory. Troubleshoot rear window washer malfunctions by performing OBD program using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding". Rear window washer system, checking with Output Diagnostic Test Mode (DTM) Rear window wiper system operation can be checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module J Connect Vehicle Diagnostic, Testing and Information System VAS 5051/ , VAS 5051 / Select operating mode "Guided Fault Finding" - Enter information as prompted and press ">" to confirm. After the DTC memory of all control modules has been checked:

39 Rear Window Washer System Page 2 / 5 - Use "Go to" button to select "Function / Component Selection" - Select "Body (Repair Group 01; 27; 50-97)" - Select "Electrical system int/ext (Repair Group 01; 27; 90-97)" - Select "01 - Self-diagnosis" - Select "Vehicle Electrical System Control Module" - Select "Vehicle Electrical System Control Module functions" - Select "J519 - output DTM, sequential (Repair Group 97)" - Select "1 - Output Diagnostic Test Mode (DTM) for an individual component" - Select "Another actuator" until selection for "Rear window washer" is displayed - Follow tester prompts Rear window washer system, component overview

40 Rear Window Washer System Page 3 / 5 Coupling Washer hose coupling between passenger compartment and rear lid Overview 92-6, Washer Hose Couplings Coupling Washer hose coupling to rear window washer jet Overview 92-6, Washer Hose Couplings Rear window washer jet Removing and installing 92-4, Rear window washer

41 Rear Window Washer System Page 4 / 5 jet, removing and installing Checking and adjusting 92-4, Rear window washer jet, checking and adjusting Washer fluid reservoir filling tube Removing and installing 92-2, Washer fluid reservoir, removing and installing Washer fluid reservoir Removing and installing 92-2, Washer fluid reservoir, removing and installing Angle coupling Connection to Windshield and Rear Window Washer Pump V59 Overview 92-6, Washer Hose Couplings Windshield and Rear Window Washer Pump V59 Removing and installing 92-2, Windshield and Rear Window Washer Pump V59, removing and installing Windshield Washer Fluid Level Sensor G33 Removing and installing 92-2, Windshield Washer Fluid Level Sensor G33, removing and installing Washer hose Hose repair 92-7, Washer Hose Repair

42 Rear Window Washer System Page 5 / 5 Rear window washer jet, removing and installing Removing: - Switch ignition on and momentarily activate rear wiper in order to ensure wiper returns to park position. Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Fold back cap on rear window wiper arm. - Use appropriate pliers to pull washer jet out from wiper shaft - arrow -. Installing: - Insert washer jet with (washer jet opening facing upwards) into wiper shaft as far as possible. - Adjust washer jet 92-4, Rear window washer jet, checking and adjusting. Rear window washer jet, checking and adjusting Repair Manual, Maintenance, Repair Group 00,

43 Volkswagen Golf 5 - Headlamp Washer System Page 1 / 9 Volkswagen Technical Site: Headlamp Washer System General information Every fifth time the windshield washers are used, the headlamp washers are activated automatically when the windshield washer switch is operated and held for at least 1.5 seconds (headlamps must be turned on - low or high beam). The activation time delay of the headlamp washer system can be adjusted between 0 and seconds 97-5, Headlamp washer system, adaptation. After any disassembly/reassembly operations are performed to the headlamp washer system, the system must be bled and operation confirmed 92-5, Headlamp washer system, bleeding. Note: Additional information: Owners Manual Wiring Diagrams Component Locations On Board Diagnostic, functions Headlamp washer system functions are controlled by the Vehicle Electrical System Control Module J519 which has On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory. Troubleshoot headlamp washer system malfunctions by performing OBD program using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding". Headlamp washer system, component overview

44 Headlamp Washer System Page 2 / 9 Right headlamp washer jet with telescoping cylinder Washer jet retainer, removing and installing 92-5, Headlamp washer jet retainer, removing and installing Washer jets, adjusting 92-5, Headlamp washer jets, checking and adjusting Telescoping cylinder, removing and installing 92-5, Headlamp washer jet telescoping cylinder, removing and installing Left headlamp washer jet with telescoping cylinder

45 Headlamp Washer System Page 3 / 9 Washer jet retainer, removing and installing 92-5, Headlamp washer jet retainer, removing and installing Washer jets, adjusting 92-5, Headlamp washer jets, checking and adjusting Telescoping cylinder, removing and installing 92-5, Headlamp washer jet telescoping cylinder, removing and installing Angle coupling Washer hose coupling to left washer jet Overview 92-6, Washer Hose Couplings Hose Angle coupling Coupling to right washer jet telescoping cylinder Divides washer fluid line to washer jets of headlamp cleaning system Overview 92-6, Washer Hose Couplings T-piece Divides washer fluid line to washer jets of headlamp cleaning system Angle coupling Washer fluid reservoir filling tube Removing and installing 92-2, Washer fluid reservoir, removing and installing

46 Headlamp Washer System Page 4 / 9 Washer fluid reservoir Removing and installing 92-2, Washer fluid reservoir, removing and installing Angle coupling Connection to Headlamp Washer Pump V11 Overview 92-6, Washer Hose Couplings Headlamp Washer Pump V11 Removing and installing 92-5, Headlamp Washer Pump V11, removing and installing Windshield Washer Fluid Level Sensor G33 Removing and installing 92-2, Windshield Washer Fluid Level Sensor G33, removing and installing Headlamp Washer Pump V11, removing and installing Headlamp Washer Pump V11 is installed in washer fluid reservoir in right wheel housing. Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove front bumper cover Repair Manual, Body Exterior, Repair Group 63, Front

47 Headlamp Washer System Page 5 / 9 bumper. - Remove Headlamp Washer Pump V upward from reservoir. - Disconnect electrical connection To disassemble connecting tube - 8 -, pull securing clip at connection and pull connecting tube from Headlamp Washer Pump V11. Installing: Install in reverse order of removal, noting the following: - Tighten all fasteners according to values in table 92-8, Wiper and Washer Systems, tightening torques. - Bleed headlamp washer system after completing assembly work 92-5, Headlamp washer system, bleeding. Headlamp washer jet telescoping cylinder, removing and installing Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key.

48 Headlamp Washer System Page 6 / 9 - Remove washer jets with cover up to stop from bumper cover. - Unclip cover from retainers - arrows - on telescoping cylinder. - Remove front bumper cover Repair Manual, Body Exterior, Repair Group 63, Front bumper. - Pull off securing clip from hose connection. - Disconnect hose connection from telescoping cylinder Remove screw Unclip telescoping cylinder from bracket Installing: Install in reverse order of removal, noting the following: - Washer hose to telescoping cylinder must be clipped into bracket.

49 Headlamp Washer System Page 7 / 9 - Tighten all fasteners according to values in table 92-8, Wiper and Washer Systems, tightening torques. - Bleed headlamp washer system after completing assembly work 92-5, Headlamp washer system, bleeding. Headlamp washer jet retainer, removing and installing Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove washer jet with cover up to stop from bumper cover. - Unclip cover from retainer - arrows -.

50 Headlamp Washer System Page 8 / 9 - Lift lug - arrow - slightly and pull out washer jet holder. Installing: Note: With the lugs on the washer jet holder, it can be adjusted how strongly the washer jet cover is fastened onto bumper cover. If washer jet holder is not slid in far enough, cover does not close. If washer jet holder is slid in too forcefully, cover and bumper cover may be deformed. - Slide washer jet holder into telescoping cylinder until it engages. - Install cover onto washer jet holder and let down telescoping cylinder. - Check cover for correct seating on bumper cover. - Adjust cover if necessary by shifting washer jet holder into a higher or lower catch on the telescoping cylinder. - Bleed headlamp washer system after completing assembly work 92-5, Headlamp washer system, bleeding. - Check washer jets for headlamp cleaning system and adjust if necessary 92-5, Headlamp washer jets, checking and adjusting. Headlamp washer jets, checking and adjusting

51 Headlamp Washer System Page 9 / 9 Repair Manual, Maintenance, Repair Group 00, Headlamp washer system, bleeding After any disassembly/reassembly operations are performed to the headlamp washer system, the system must be bled and operation confirmed. Proceed as follows: - Fill washer fluid reservoir. Warning! Engage handbrake and ensure transmission is in range "P". - Switch on ignition. - Switch on headlamps. - Operate windshield washer switch intermittently, with 3-5 impulses over a 3 second period (washer jet cylinder should momentarily engage/raise/lower). - Repeat procedure until all air has been bled from system and washer jet cylinder engages/raises immediately and consistently.

52 Volkswagen Golf 5 - Washer Hose Couplings Page 1 / Washer Hose Couplings General information Several different designs of washer hose couplings are used in the windshield, rear window (where applicable) and headlamp washer systems. Each coupling requires specific actions in order to disconnect and reconnect. Windshield and rear window washer system - Disconnect by pulling apart both halves of coupling. - Reconnect by pushing both halves of coupling together until felt and heard to engage. - Disconnect by turning lock ring through 90 - arrow - and then pulling apart both halves of coupling. - Reconnect by pushing both halves of coupling together and rotating locking ring arrow - until it engages.

53 Washer Hose Couplings Page 2 / 2 - Disconnect by lifting lock ring approx. 1 mm - arrow - and then pulling apart both halves of coupling. - Reconnect by pushing both halves of coupling together and clipping locking ring until it engages. Headlamp washer pump - Disconnect by depressing clip in direction of - arrow - and then separating coupling from jet. - Reconnect by keeping clip - arrow - depressed while pushing coupling onto jet until it engages. - Check for proper fit by attempting to separate coupling without depressing clip.

54 Volkswagen Golf 5 - Washer Hose Repair Page 1 / Washer Hose Repair General information A concept has been developed to facilitate the repair of washer hoses. Various individual hose connectors, adaptors, Ethylene Propylene Diene Methylene (EPDM) rubber hoses and shrink tubing will be offered as replacement parts. Note: For part numbers, see Parts Catalog. Repair parts will be available for both smooth and corrugated hoses. Smooth hoses, repairing Smooth hoses with a diameter of 5 x 1 mm or 6 x 1 mm can be repaired with a EPDM repair hose section. - Trim and remove damaged sections of hose. - Choose matching EPDM repair hose and cable ties from Parts Catalog - Insert hose and into ends of EPDM repair hose to a depth of at least 10 mm - 2-.

55 Washer Hose Repair Page 2 / 3 - Secure with cable ties as illustrated. Corrugated hoses, repairing Special tools, testers and auxiliary items required Hot air gun VAS 1978/14 or Hot air gun kit VAS 5179 as illustrated Note: Area to be repaired must not be under stress of stretching or bending. If damaged area is longer than 20 mm, a new section of corrugated hose must be obtained, and two sets of adapters inserted using following the following procedure. - Trim and remove damaged sections of hose.

56 Washer Hose Repair Page 3 / 3 - Choose matching repair adapters and and appropriate shrink tubing from Parts Catalog. - Carefully warm end of hose Insert repair adapter into hose - 2--arrow A-. - Carefully warm end of hose Insert repair adapter into hose - 4--arrow B-. - Trim shrink tubing sections so that corrugated hose is covered a minimum of 20 mm - dimension x -. - Slide shrink tubing over corrugated hose, attach adapters together and secure repair with shrink tubing.

57 Volkswagen Golf 5 - Wiper and Washer Systems, tightening torques Page 1 / Wiper and Washer Systems, tightening torques Location / fastener Tightening torque Wiper motor to wiper frame / bolts M6 8 Nm Motor crank to wiper motor shaft / nut M8 18 Nm Wiper assembly to body / bolts M6 8 Nm Front wiper arm to wiper motor shaft / nuts M8 20 Nm Washer fluid reservoir to body / bolts M6 8 Nm Rear wiper arm to rear wiper motor shaft / nut M8 12 Nm Rear wiper motor assembly to rear lid / bolts M6 8 Nm Headlamp washer telescoping cylinder to front bumper cover / bolts 4.5 Nm