Lights, Switches - Exterior Page 1 / 2 Volkswagen Golf 5 2004-> VW Rabbit GTI 2006-> 94-1 Lights, Switches - Exterior General information Before troubleshooting or servicing, technicians must be familiar with the functions and operation specifics of the standard or optional headlamp or lighting system. Always read the owners manual and review applicable system functions. Additional information: Owners Manual Self Study Program - Course Number 892503 "VW 2006 GTI Introduction" Wiring Diagrams Component Locations On Board Diagnostic, functions Exterior light 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 exterior light system malfunctions by performing OBD program using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding". Lights, Switches - exterior, checking with Output Diagnostic Test Mode (DTM) The function of many exterior lights and switches can be checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module J519. - Connect Vehicle Diagnostic, Testing and Information System VAS 5051/5052 97-1, VAS 5051 / 5052 - Select operating mode "Guided Fault Finding" - Enter information as prompted and press ">" to confirm. After the DTC memory of all control modules has been
Lights, Switches - Exterior Page 2 / 2 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" - Search and select appropriate light or switch component from menu, or - Select "2 - Output Diagnostic Test Mode (DTM) for all actuators" - Follow tester prompts
Headlamps Page 1 / 24 94-2 Headlamps General information Before troubleshooting or servicing, technicians must be familiar with the functions and operation specifics of the standard or optional headlamp or lighting system. Always read the owners manual and review applicable system functions. Additional information: Owners Manual Self Study Program - Course Number 892503 "VW 2006 GTI Introduction" Wiring Diagrams Component Locations Headlamps from several manufacturers are installed: AL (Automotive Lighting) Hella Visteon Assembly and disassembly of headlamps and their attachments is identical up to removing and installing positioning motors. Caution! Before beginning repairs on electrical system Switch off all electrical consumers. Switch ignition off and remove ignition key. On Board Diagnostic, functions Headlamp 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)
Headlamps Page 2 / 24 will be stored in memory. Troubleshoot headlamp system malfunctions by performing OBD program using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding". Headlamps, checking with Output Diagnostic Test Mode (DTM) Headlamp function (including turn signals and parking light) can be checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module J519. - Connect Vehicle Diagnostic, Testing and Information System VAS 5051/5052 97-1, VAS 5051 / 5052 - 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" - Search and select appropriate light or switch component from menu, or - Select "2 - Output Diagnostic Test Mode (DTM) for all actuators" - Follow tester prompts
Headlamps Page 3 / 24 Headlamps, assembly After performing any repairs or service that could affect headlamp aim, check/adjust aim Repair Manual, Maintenance, Repair Group 00, The following headlamp assembly exploded view depicts various manual headlamp range control system motors (manufacturer-dependent) that are not applicable to USA/CDN models. Please disregard these components. Tightening torques 94-12, Headlamps, tightening torques
Headlamps Page 4 / 24 Screws 4 Nm Adjustment guide Correcting installation position of headlamp 94-2, Headlamp installation position, correcting Left High Beam Headlamp M30 and Right High Beam Headlamp M32 Lamp H7U 12 V, 55 W Replacing 94-2, High Beam Headlamp bulb M30 / M32, replacing Left Parking Light M1 and Right Parking Light M3 Lamp 12 V, W 5 W Replacing 94-2, Parking Lamp bulb M1 / M3, replacing Cover Left Front Turn Signal Light M5 and Right Front Turn Signal Light M7 Lamp 12 V, PY 21 W Replacing 94-2, Front Turn Signal Lamp bulb M5 / M7, replacing Bulb holder for Left Front Turn Signal Light M5 and Right Front Turn Signal Light M7 Lock carrier
Headlamps Page 5 / 24 Not applicable to USA/CDN models Cover Screws only with manufacturer: AL (Automotive Lighting) for Left Headlamp Beam Adjusting Motor V48 and Right Headlamp Beam Adjusting Motor V49 Not applicable to USA/CDN models Lock ring Not applicable to USA/CDN models Lock ring Bulb holder for Left Low Beam Headlamp M29 and Right Low Beam Headlamp M31 Left Low Beam Headlamp M29 and Right Low Beam Headlamp M31 Bulb H7 12 V, 55 W Replacing 94-2, Low Beam Headlamp bulb M29 / M31, replacing Headlamp housing Removing and installing 94-2, Headlamps, removing and installing Correcting installation position of headlamp 94-2, Headlamp installation position, correcting Servicing headlamp securing
Headlamps Page 6 / 24 lugs 94-2, Headlamp securing lugs, servicing Headlamps, removing and installing Headlamp, removing: It is not necessary to disconnect battery. It is not necessary remove front bumper in order to remove headlamp. Removal of left headlamp is illustrated. Removal of right headlamp is the same. If one headlamp is removed, it must always be adjusted after installation. Repair Manual, Maintenance, Repair Group 00, Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Release and disconnect electrical connection - arrow -.
Headlamps Page 7 / 24 - Remove front grille assembly. Repair Manual, Body Exterior, Repair Group 66, - Remove front bumper trim strip. Repair Manual, Body Exterior, Repair Group 63, - Remove screw - arrow - at lower left of headlamp. - Remove screw - arrow - at lower right of headlamp.
Headlamps Page 8 / 24 - Remove screws - arrow - at top of headlamp. - Remove headlamp from body opening. Headlamp, installing Install in reverse order of removal, noting the following: - Tighten all fasteners according to value in table 94-12, Headlamps, tightening torques. - Check the installed position of the headlamp for uniform gap dimensions. If headlamp has an uneven gap dimension to the body, installation position must be corrected 94-2, Headlamp installation position, correcting. - Check headlamp function. If one headlamp is removed, it must always be adjusted after installation. - Check headlamp aim and adjust if necessary. Repair Manual, Maintenance, Repair Group 00, Headlamp installation position, correcting If during the check of the final installation position it is established that headlamp gaps are uneven with the body, correct installation position as follows:
Headlamps Page 9 / 24 In order to correct the installation position of the headlamp, front bumper must not be removed. Procedure at left headlamp is illustrated. Procedure for right headlamp is the same. Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove radiator grille assembly. Repair Manual, Body Exterior, Repair Group 66, - Loosen screw - arrow - at top of headlamp. - When not previously removed, remove front bumper trim strip. Repair Manual, Body Exterior, Repair Group 63,
Headlamps Page 10 / 24 - Loosen screw - arrow - at lower left of headlamp. - Loosen screw - arrow - at lower right of headlamp. - Adapt surface alignment of headlamp housing to body by screwing the adjustment guides in or out - arrow-. - Tighten all fasteners according to values in table 94-12, Headlamps, tightening torques. - Check and if necessary correct installation position of headlamp again for uniform gap dimension. - Install radiator grille
Headlamps Page 11 / 24 Repair Manual, Body Exterior, Repair Group 66,. - Check headlamp function. If one headlamp is removed, it must always be adjusted after installation. - Check headlamp aim and adjust if necessary. Repair Manual, Maintenance, Repair Group 00, Headlamp bulbs, replacing Low Beam Headlamp bulb M29 / M31, replacing Replacement of Left Low Beam Headlamp M29 is illustrated. Procedure for right headlamp is the same. Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key.
Headlamps Page 12 / 24 - Turn cover - 1 - in direction of - arrow - and remove. - Turn bulb holder with bulb - 1 - in direction of - arrow - and remove. - Remove bulb - 2 - in direction of - arrow - from bulb holder - 1 -. Installing: Caution! Do not touch glass portion of bulb with bare hands. Even the smallest amount of moisture and/or contaminants from fingers that evaporates on the bulb during operation can cause the glass to cloud over. When installing cap, ensure proper seating. Water intrusion will damage headlamp.
Headlamps Page 13 / 24 - Insert bulb - 1 - into bulb holder so that pin fits in recess - arrow - of bulb holder - 2 -. - Insert bulb holder with bulb - 1 - into headlamp and rotate bulb holder in direction of - arrow -. - Insert cover - 1 - into recess on headlamp and tighten cover in direction - arrow -. - Check headlamp function. - Check headlamp aim and adjust if necessary Repair Manual, Maintenance, Repair Group 00,
Headlamps Page 14 / 24. High Beam Headlamp bulb M30 / M32, replacing Replacement of Left High Beam Headlamp M30 is illustrated. Procedure for right headlamp is the same. Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove cover - 1 -. - Disconnect electrical connection - 1 -.
Headlamps Page 15 / 24 - Press spring retaining wire - 2 - in direction of - arrow - under catches - 1 - and fold spring retaining wire - 2 - upward. - Remove bulb - 1 - from headlamp housing. Installing: Caution! Do not touch glass portion of bulb with bare hands. Even the smallest amount of moisture and/or contaminants from fingers that evaporates on the bulb during operation can cause the glass to cloud over. When installing cap, ensure proper seating. Water intrusion will damage headlamp. Install in reverse order of removal, noting the following:
Headlamps Page 16 / 24 - Insert bulb - 1 - into recesses - arrows - on headlamp. - Check headlamp function. - Check headlamp aim and adjust if necessary. Repair Manual, Maintenance, Repair Group 00, Parking Lamp bulb M1 / M3, replacing Replacement of Left Parking Lamp M1 is illustrated. Procedure for right headlamp is the same. Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key.
Headlamps Page 17 / 24 - Remove cover - 1 -. - Pull bulb holder - 1 - with bulb from reflector as far as electrical cable permits. - Remove bulb - 2 - in direction of - arrow - from socket - 1 -. Installing: Caution! Do not touch glass portion of bulb with bare hands. Even the smallest amount of moisture and/or contaminants from fingers that evaporates on the bulb during operation can cause the glass to cloud over. When installing cap, ensure proper seating. Water intrusion will damage headlamp. Install in reverse order of removal, noting the following: - Check bulb function. - Check headlamp aim and adjust if necessary
Headlamps Page 18 / 24 Repair Manual, Maintenance, Repair Group 00,. Front Turn Signal Lamp bulb M5 / M7, replacing Replacement of Left Front Turn Signal Lamp M5 is illustrated. Procedure for right headlamp is the same. Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Turn bulb holder with bulb - 1 - in direction of - arrow - and remove. - Push bulb into socket, twist counter-clockwise and remove from socket. Installing: Caution! Do not touch glass portion of bulb with bare hands. Even the smallest amount of moisture and/or contaminants from fingers that evaporates on the bulb during operation can cause the glass to cloud over. When installing bulb holder, ensure proper
Headlamps Page 19 / 24 seating. Water intrusion will damage headlamp. Install in reverse order of removal, noting the following: - Check bulb function. - Check headlamp aim and adjust if necessary. Repair Manual, Maintenance, Repair Group 00, Headlamp securing lugs, servicing Should headlight securing lugs - 1 -, - 2 - or - 3 - break due to application of excessive force, it may still be possible to service headlight in a cost effective manner (though headlight housing itself must not be damaged). Repair procedure for standard headlamps and headlamps with High Intensity Gas Discharge (HID) lamps is the same as described below. In the event an HID headlamp requires repair, read, understand and observe all safety precautions for servicing HID lamps 94-3, General information. Ensure there is no additional damage to headlamp that cannot be fixed by installing repair kit. There are two different repair kits for left and right headlamps Parts Catalog. Each repair kit contains upper, outer and lower headlamp securing lugs, four screws, a nut already
Headlamps Page 20 / 24 installed on upper securing lug and a pre-installed adjustment bushing on outer and lower securing lugs. - Upper securing lug repair 94-2, Upper securing lug, repairing. - Outer securing lug repair 94-2, Outer securing lug, repairing. - Lower securing lug repair 94-2, Lower securing lug, repairing. Upper securing lug, repairing Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove affected headlamp 94-2, Headlamps, removing and installing, or remove affected HID headlamp 94-3, HID Headlamps, removing and installing. - Completely remove old headlamp securing lug - 1 - from headlamp.
Headlamps Page 21 / 24 - Position new securing lug - 2 - on tab base on headlamp - 4 - and tighten securing lug - 3 -. Nut - 1 - is already installed on securing lug - 2 -. - Install headlamp 94-2, Headlamp, installing, or install HID headlamp 94-3, HID Headlamp, installing. - Check headlamp aim and adjust if necessary Repair Manual, Maintenance, Repair Group 00,. Outer securing lug, repairing Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove affected headlamp 94-2, Headlamps, removing and installing, or remove affected HID headlamp 94-3, HID Headlamps, removing and installing.
Headlamps Page 22 / 24 - Completely remove old headlamp securing lug - arrow - from headlamp. - Position new securing lug - 3 - on tab base on headlamp - 1 - and tighten securing lug - 2 -. Adjustment bushing - 4 - is already installed on securing lug - 3 -. - Install headlamp 94-2, Headlamp, installing, or install HID headlamp 94-3, HID Headlamp, installing. - Check headlamp aim and adjust if necessary Repair Manual, Maintenance, Repair Group 00,. Lower securing lug, repairing Caution! Switch off all electrical consumers.
Headlamps Page 23 / 24 Switch ignition off and remove ignition key. - Remove affected headlamp 94-2, Headlamps, removing and installing, or remove affected HID headlamp 94-3, HID Headlamps, removing and installing. - Completely remove old headlamp securing lug - arrow - from headlamp. - Position new securing lug - 3 - on tab base on headlamp - 1 - and tighten securing lug - 2 -. - Then tighten securing lug - 5 - on rear side. Adjustment bushing - 4 - is already installed on securing lug - 3 -. - Install headlamp 94-2, Headlamp, installing, or install
Headlamps Page 24 / 24 HID headlamp 94-3, HID Headlamp, installing. - Check headlamp aim and adjust if necessary. Repair Manual, Maintenance, Repair Group 00, Headlamps, adjusting Headlamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and specifications. Repair Manual, Maintenance, Repair Group 00,
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 1 / 30 94-3 Headlamps with High Intensity Gas Discharge (HID) Lamps General information Warning! HIGH VOLTAGE! The physical and mechanical properties of HID bulbs are very sensitive. Internal pressure of HID glass bulb may exceed 100 bar (in operation). Bulb temperature may exceed 700 degrees Celsius. Danger of explosion and burning. The control modules for HID lamps must never be operated (headlamps turned on) without an HID lamp. HID bulbs must only be operated (headlamps turned on) when installed in the headlamp housing. Always wear safety glasses and gloves when removing and installing HID bulb. Never look directly at an operating HID bulb. The UV emissions of an HID bulb are approximately 2.5 times that of a comparable halogen bulb.. Before troubleshooting or servicing, technicians must be familiar with the functions and operation specifics of the standard or optional headlamp or lighting system. Always read the owners manual and review applicable system functions. Additional information: Owners Manual Self Study Program - Course Number 892503 "VW 2006
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 2 / 30 GTI Introduction" Wiring Diagrams Component Locations Caution! Before beginning repairs on electrical system Switch off all electrical consumers. Switch ignition off and remove ignition key. On Board Diagnostic, functions HID headlamp and automatic vertical headlamp beam adjusting system have On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory. Troubleshoot headlamp system malfunctions by performing OBD program using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding". Headlamps with High Intensity Gas Discharge (HID) lamps - automatic vertical headlight aim control, checking with Output Diagnostic Test Mode (DTM) HID headlamp functions (including turn signals, parking light and automatic vertical headlamp beam adjusting system operation) can be checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module J519. - Connect Vehicle Diagnostic, Testing and Information System VAS 5051/5052 97-1, VAS 5051 / 5052 - 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)"
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 3 / 30 - Select "01 - Self-diagnosis" - Select "Automatic vertical headlight aim control" - Select "Functions" - Select "Output Diagnostic Test Mode (DTM)" - Press ">" to confirm. - Follow tester prompts Headlamps with High Intensity Gas Discharge (HID) Lamps, assembly Note : After performing any repairs or service that could affect headlamp aim, check/adjust aim Repair Manual, Maintenance, Repair Group 00, Tightening torques 94-12, Headlamps, tightening torques
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 4 / 30 Ventilation hose on headlamp Left Headlamp Beam Adjusting Motor V48 and Right Headlamp Beam Adjusting Motor V49 Note : Headlamp manufacturer: AL (Automotive Lighting) The initial removal of Left Headlamp Beam Adjustment Motor V48 and Right Headlamp Beam Adjustment Motor V49 requires a repair set Parts Catalog Screws
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 5 / 30 for Left Headlamp Beam Adjusting Motor V48 and Right Headlamp Beam Adjusting Motor V49 Cover HID Lamp Igniter Unit N195 HID Bulb retainer for Left High Intensity Gas Discharge (HID) Lamp L13 and Right High Intensity Gas Discharge (HID) Lamp L14 Left High Intensity Gas Discharge (HID) Lamp L13 and Right High Intensity Gas Discharge (HID) Lamp L14 Type D2S, 35W Replacing 94-3, High Intensity Gas Discharge (HID) Lamp bulb L13 / L14, replacing Screw 4 Nm on top of headlamp Headlamp housing Removing and installing 94-2, Headlamps, removing and installing Correcting installation position of headlamp 94-2, Headlamp installation position, correcting Servicing headlamp securing lugs 94-2, Headlamp securing lugs, servicing Headlamp Range Control Module J431
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 6 / 30 Removing and installing 94-3, Headlamp Range Control Module J431, servicing Note : Coding 94-3, Headlamp Range Control Module J431, coding If Headlamp Range Control Module J431 is coded, headlamp basic settings must be performed after coding the control module Repair Manual, Maintenance, Repair Group 00,. Left Front Level Control System Sensor G78 Removing and installing 94-3, Level Control System Sensors G76 / G78, servicing Checking 94-3, Level Control System Sensors G76 / G78, checking Left Rear Level Control System Sensor G76 Removing and installing 94-3, Level Control System Sensors G76 / G78, servicing Checking 94-3, Level Control System Sensors G76 / G78, checking Adjustment guide Correcting installation position of headlamp 94-2, Headlamp installation
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 7 / 30 position, correcting Screw 4 Nm on headlamp at bottom Left High-intensity Gas Discharge Lamp Control Module J343 and Right High-intensity Gas Discharge Lamp Control Module J344 not capable of On Board Diagnostic (OBD) Removing and installing 94-3, High-intensity Gas Discharge Lamp Control Modules J343 / J344, removing and installing Screws for Left High-intensity Gas Discharge Lamp Control Module J343 and Right High-intensity Gas Discharge Lamp Control Module J344 Left High Beam Headlamp M30 and Right High Beam Headlamp M32 Lamp H7U 12 V, 55 W Replacing 94-3, High Beam Headlamp bulb M30 / M32, replacing Left Front Turn Signal Light M5 and Right Front Turn Signal Light M7 Lamp 12 V, H2 WLL 21 W Replacing 94-3, Front Turn Signal Lamp bulb M5 / M7, replacing
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 8 / 30 Left Parking Light M1 and Right Parking Light M3 Lamp 12 V, W 5 W Replacing 94-3, Parking Lamp bulb M1 / M3, replacing Cover for Left Front Turn Signal Lamp M5 and Right Front Turn Signal Lamp M7 and for Left Parking Lamp M1 and Right Parking Lamp M3 Cover for Left High Beam Headlamp M30 and Right High Beam Headlamp M32 HID Headlamps, removing and installing HID Headlamp, removing Read, understand and observe all safety precautions for servicing HID lamps 94-3, General information. It is not necessary to disconnect battery. Removal of left headlamp is illustrated. Removal of right headlamp is the same. Perform basic setting after installation. Repair Manual, Maintenance, Repair Group 00,
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 9 / 30 If one headlamp is removed, it must always be adjusted after installation. Repair Manual, Maintenance, Repair Group 00, Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove front bumper cover. Repair Manual, Body Exterior, Repair Group 63, - Release and disconnect electrical connection - arrow -.
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 10 / 30 - Remove screw - arrow - at right of headlamp. - Remove screw - arrow - at lower left of headlamp. - Remove screw - arrow - at top of headlamp. - Remove headlamp from body opening. HID Headlamp, installing Install in reverse order of removal, noting the following: - Tighten all fasteners according to value in table 94-12, Headlamps, tightening torques. - Check the installed position of the headlamp for uniform gap dimensions. If headlamp has an uneven gap dimension to the body, installation position must be corrected 94-2, Headlamp installation position, correcting. - Perform basic setting using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" Repair Manual, Maintenance, Repair Group 00,
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 11 / 30. - Check headlamp function. If one headlamp is removed, it must always be adjusted after installation. - Check headlamp aim and adjust if necessary. Repair Manual, Maintenance, Repair Group 00, Headlamp installation position, correcting Correcting installation position of headlamp 94-2, Headlamp installation position, correcting. HID Headlamp bulbs, replacing High Intensity Gas Discharge (HID) Lamp bulb L13 / L14, replacing Replacement of Left High Intensity Gas Discharge (HID) Lamp L13 is illustrated. Procedure for right headlamp is the same. Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove headlamp 94-3, HID Headlamps, removing and installing.
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 12 / 30 - Turn cover - 1 - in direction of - arrow - and remove. - Rotate igniter unit to "OPEN" position and pull straight back from bulb. Electrical connection - 1 - is automatically released when igniter is turned toward "OPEN" to stop. Warning! The physical and mechanical properties of HID bulbs are very sensitive. Internal pressure of HID glass bulb may exceed 100 bar (in operation). Bulb temperature may exceed 700 degrees Celsius. Danger of explosion and burning. Always wear safety glasses and gloves when removing and installing HID bulb.
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 13 / 30 - Rotate bulb retainer - 1 - in direction of - arrow - and remove. - Carefully remove bulb - 1 - from mounting. Installing: Caution! Do not touch glass portion of HID bulb with bare hands. Even the smallest amount of moisture and/or contaminants from fingers that evaporates on the bulb during operation can cause the glass to cloud over. When installing lamp retainer, ensure HID bulb is seated correctly in mounting. When installing cap, ensure proper seating. Water intrusion will damage headlamp. Warning! HIGH VOLTAGE! Danger of explosion and burning.
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 14 / 30 The control modules for HID lamps must never be operated (headlamps turned on) without an HID lamp. HID bulbs must only be operated (headlamps turned on) when installed in the headlamp housing. Never look directly at an operating HID bulb. The UV emissions of an HID bulb are approximately 2.5 times that of a comparable halogen bulb.. - Insert bulb into mounting. - Secure bulb by rotating bulb retainer in direction opposite to that during removal. - Insert igniter unit onto bulb terminal and rotate to "CLOSE" position. - Reconnect igniter unit electrical connection - 1-. - Refit rear lamp housing cover. - Install headlamp 94-3, HID Headlamp, installing - Check HID Lamp function. - Perform headlamp basic setting, check headlamp aim and adjust if necessary. Repair Manual, Maintenance, Repair Group 00,
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 15 / 30 High Beam Headlamp bulb M30 / M32, replacing Replacement of Left High Beam Headlamp M30 is illustrated. Procedure for right headlamp is the same. Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove cover - 1 -. - Disconnect electrical connection - arrow -.
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 16 / 30 - Press spring retaining wire - 2 - in direction of - arrow - under catches - 1 - and fold spring retaining wire - 2 - upward. - Remove bulb - 1 - from headlamp. Installing: Install in reverse order of removal, noting the following: Caution! Do not touch glass portion of bulb with bare hands. Even the smallest amount of moisture and/or contaminants from fingers that evaporates on the bulb during operation can cause the glass to cloud over. When installing cap, ensure proper seating. Water intrusion will damage headlamp.
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 17 / 30 - Insert bulb - 1 - into recesses - arrows - on headlamp. - Check headlamp function. - Check headlamp aim and adjust if necessary. Repair Manual, Maintenance, Repair Group 00, Parking Lamp bulb M1 / M3, replacing Replacement of Left Parking Lamp M1 is illustrated. Procedure for right headlamp is the same. Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key.
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 18 / 30 - Remove cover - 1 -. - Pull bulb holder - 2 - with bulb from reflector - 1 - as far as electrical cable permits. - Remove bulb - 2 - in direction of - arrow - from bulb holder - 1 -. Installing: Install in reverse order of removal, noting the following: Caution! Do not touch glass portion of bulb with bare hands. Even the smallest amount of moisture and/or contaminants from fingers that evaporates on the bulb during operation can cause the glass to cloud over. When installing cap, ensure proper seating. Water intrusion will damage headlamp. - Check bulb function. - Check headlamp aim and adjust if necessary
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 19 / 30 Repair Manual, Maintenance, Repair Group 00,. Front Turn Signal Lamp bulb M5 / M7, replacing Replacement of Left Front Turn Signal Lamp M5 is illustrated. Procedure for right headlamp is the same. Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove cover - 1 -. - Rotate bulb holder - 1 - in direction of - arrow - and remove from reflector as far as electrical cable permits.
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 20 / 30 - Push bulb - 2 - into socket - 1 - and rotate in direction of - arrow -. - Remove bulb - 2 - from bulb holder. Installing: Install in reverse order of removal, noting the following: Caution! Do not touch glass portion of bulb with bare hands. Even the smallest amount of moisture and/or contaminants from fingers that evaporates on the bulb during operation can cause the glass to cloud over. When installing cap, ensure proper seating. Water intrusion will damage headlamp. - Check bulb function. - Check headlamp aim and adjust if necessary. Repair Manual, Maintenance, Repair Group 00, Headlamp Beam Adjustment Motors V48 / V49 Headlamp beam adjusting motors, removing and installing Information not available at time of publication High-intensity Gas Discharge Lamp Control Modules J343 / J344, removing and installing
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 21 / 30 High intensity gas discharge lamp control modules do not have On Board Diagnostic (OBD) capabilities. Removing: - Remove headlamp 94-3, HID Headlamps, removing and installing. - Remove screws - arrows - at control module - 1-. When removing High-intensity Gas Discharge Lamp Control Module, no harness connectors must be disconnected. Harness connector is installed permanently on headlamp and is automatically disconnected upon removal. - Remove High-intensity Gas Discharge Lamp Control Module - 1 - from headlamp. Installing: Caution! When installing module, ensure proper seating. Water intrusion will damage headlamp. Install in reverse order of removal, noting the following: - Check HID Lamp function. - Perform headlamp basic setting, check headlamp aim and adjust if necessary. Repair Manual, Maintenance, Repair Group 00,
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 22 / 30 Headlamp Range Control Module J431, servicing Headlamp Range Control Module J431, removing and installing Special tools, testers and auxiliary items required Trim removal wedge VAS 3409 Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. When removing switches, trim, covers or displays, prevent damage to visible areas always applying appropriate tape to area surrounding the component, and the tools being used (screwdrivers, wedges etc.). Removing:
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 23 / 30 - Remove right instrument panel side cover - 1 - by inserting trim removal wedge VAS 3409 or a screwdriver into recess - 2 - and pry off cover - 1 - in direction of - arrow -. - Disengage lock - 1 - in direction of - arrow - and disconnect electrical connection - 2 - from control module.
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 24 / 30 - Remove screw - arrow - and remove control module - 1 - from bracket - 2 -. Installing: Install in reverse order of removal, noting the following: - Insert control module - 3 - with retaining clip - 2 - in bracket - 1 -.
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 25 / 30 - Secure electrical connection - 1 - by engaging lock - 2 - in direction of - arrow -. After installing a new Headlamp Range Control Module J431, it must be coded 94-3, Headlamp Range Control Module J431, coding. Headlamp Range Control Module J431, coding - Connect Vehicle Diagnostic, Testing and Information System VAS 5051/5052 97-1, VAS 5051 / 5052 - Connect Vehicle Diagnostic, Testing and Information System VAS 5051/5052 97-1, VAS 5051 / 5052 - 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 "Automatic vertical headlight aim control" - Select "Functions" - Select "Coding automatic vertical headlight aim control" - Follow tester prompts After coding Headlamp Range Control Module J431, headlamp basic setting must be performed. Repair Manual, Maintenance, Repair Group 00, Level Control System Sensors G76 / G78, servicing
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 26 / 30 Level sensors are installed on one side of the front and rear suspension. If the vehicle level sensors are replaced, the values of the sensor must be checked and headlamp basic setting must be performed. If values of vehicle level sensors are outside the tolerance range, headlamp basic settings cannot be performed. Left Front Level Control System Sensor G78, removing and installing Location: Sensor assembly is installed on left front suspension subframe console and is connected to the left front lower control arm with a relay lever. Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Disconnect electrical connection - arrow -.
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 27 / 30 - Remove nut - 1 -. - Remove bolt - 2 - and remove sensor - 3-. Installing: Install in reverse order of removal, noting the following: - Tighten all fasteners according to values in table 94-12, Vehicle level sensors, tightening torques:. - Check Left Front Level Control System Sensor G78 94-3, Level Control System Sensors G76 / G78, checking. - Perform headlamp basic setting. Repair Manual, Maintenance, Repair Group 00, If the vehicle level sensors are replaced, the values of the sensor must be checked and headlamp basic must be performed. If values of vehicle level sensors are outside the tolerance range, headlamp basic settings cannot be performed. Left Rear Level Control System Sensor G76, removing and installing Location: Sensor assembly is installed on left rear suspension subframe and is connected to the left lower transverse link with a relay lever. Removing:
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 28 / 30 Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Disconnect electrical connection - arrow -. - Remove screws - 1 - and remove sensor assembly - 2 - from suspension components. Installing: Install in reverse order of removal, noting the following: - Tighten all fasteners according to values in table 94-12, Vehicle level sensors, tightening torques:. - Check Left Rear Level Control System Sensor G76 94-3, Level Control System Sensors G76 / G78, checking. - Perform headlamp basic setting Repair Manual, Maintenance, Repair Group 00,
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 29 / 30. If the vehicle level sensors are replaced, the values of the sensor must be checked and headlamp basic settings must be performed. If values of vehicle level sensors are outside the tolerance range, headlamp basic settings cannot be performed. Level Control System Sensors G76 / G78, checking General information: Vehicle Level Sensors transmit a Pulse Width Modulation (PWM) signal (representing vehicle attitude, load etc. ) to the Headlamp Range Control Module J431. The checking procedure determines if the signals produced by Left Rear Level Control System Sensor G76 and Left Front Level Control System Sensor G78 are evaluated by Headlamp Range Control Module J431. In the following cases, no DTC are stored in Headlamp Range Control Module J431 memory: when vehicle level sensors are not installed as specified in the Repair Manual when vehicle level sensors are damaged mechanically when vehicles have a modified axle geometry (e.g. lowered vehicle) If values of vehicle level sensors are outside the tolerance range, headlamp basic setting cannot be performed. - Connect Vehicle Diagnostic, Testing and Information System VAS 5051/5052 97-1, VAS 5051 / 5052 - Select operating mode "Guided Fault Finding" - Enter information as prompted and press ">" to confirm.
Headlamps with High Intensity Gas Discharge (HID) Lamps Page 30 / 30 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 "Automatic vertical headlight aim control" - Select "Functions" - Select "Check level control system sensor" - Follow tester prompts HID Headlamp securing lugs, servicing Headlamp securing lugs, servicing securing lugs, servicing. 94-2, Headlamp HID Headlamps, adjusting Headlamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and specifications. Repair Manual, Maintenance, Repair Group 00,
Fog Lamps Page 1 / 6 94-4 Fog Lamps General information Where applicable, two quartz-halogen fog lamps are located in the lower front bumper valance panel. Additional information: Owners Manual Self Study Program - Course Number 892503 "VW 2006 GTI Introduction" Wiring Diagrams Component Locations On Board Diagnostic, functions Fog lamp 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 fog lamp system malfunctions by performing OBD program using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding". Fog lamps, checking with Output Diagnostic Test Mode (DTM) Fog lamp function can be checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module J519. - Connect Vehicle Diagnostic, Testing and Information System VAS 5051/5052 97-1, VAS 5051 / 5052 - 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"
Fog Lamps Page 2 / 6 - 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 "4 - Fog light left/right" - Follow tester prompts Fog lamps, assembly Tightening torques torques: 94-12, Fog lamps, tightening
Fog Lamps Page 3 / 6 1 - Front bumper cover 2 - Ventilation hose 3 - Left Front Fog Lamp L22 and Right Front Fog Lamp L23 Lamp H11 12 V, 55 W Removing and installing 94-4, Front Fog Lamp bulb L22 / L23, removing and installing 4 - Fog lamp housing Removing and installing 94-4, Fog lamp housing, removing and installing 5 - Cover 6 - Screws
Fog Lamps Page 4 / 6 7 - Expanding nuts Fog lamp housing, removing and installing Removal and installation of left fog lamp housing is illustrated. Procedure for right fog lamp is the same. Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Unclip cover - 1 - from retainers. - Remove screws - arrows -.
Fog Lamps Page 5 / 6 - Remove fog light housing from bumper cover and disconnect electrical connection - arrow -. Installing: Install in reverse order of removal, noting the following: - Check fog lamp function. - Check fog lamp adjustment and adjust if necessary. Repair Manual, Maintenance, Repair Group 00, Front Fog Lamp bulb L22 / L23, removing and installing Replacement of Left Front Fog Lamp L22 is illustrated. Procedure for right fog lamp is the same. Removing: - Remove fog lamp housing 94-4, Fog lamp housing, removing and installing.
Fog Lamps Page 6 / 6 - Rotate bulb holder - 1 - in direction of - arrow - and remove from housing. Fog lamp bulb and bulb holder are integrated and cannot be replaced separately. Fog lamp bulb: H11 12 V, 55 W Installing: Install in reverse order of removal, noting the following: - Check fog lamp function. - Check fog lamp aim and adjust if necessary. Repair Manual, Maintenance, Repair Group 00, Fog lamps, adjusting Fog lamps are adjusted using VAS 5107 Optical Headlamp Aimer and detailed aiming procedure and specifications. Repair Manual, Maintenance, Repair Group 00,
Turn Signals and Entry Lamps in Exterior Mirrors Page 1 / 5 94-5 Turn Signals and Entry Lamps in Exterior Mirrors General information Turn signals and entry lights are integrated into the exterior mirrors. 1 - Left Mirror Turn Signal Lamp L131 and Right Mirror Turn Signal Lamp L132 2 - Drivers Entry Lamp (in outside mirror) W52 and Front Passengers Entry Lamp (in outside mirror) W53 Additional information: Owners Manual Self Study Program - Course Number 892503 "VW 2006 GTI Introduction" Wiring Diagrams Component Locations On Board Diagnostic, functions Mirror lamp 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 fog lamp system malfunctions by performing OBD program using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding". Turn signals and entry lamps in exterior mirrors,
Turn Signals and Entry Lamps in Exterior Mirrors Page 2 / 5 checking with Output Diagnostic Test Mode (DTM) Mirror lamp function can be checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module J519. - Connect Vehicle Diagnostic, Testing and Information System VAS 5051/5052 97-1, VAS 5051 / 5052 - 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. - Search and select appropriate light or switch component from menu - Follow tester prompts Exterior Mirror Turn Signal Lamps L131 / L132, removing and installing Drivers Exterior Mirror Turn Signal Lamp L131 as well as Front Passengers Exterior Mirror Turn Signal Lamp L132 are integrated into the exterior mirror housings. In case of damage, the entire Drivers Exterior Mirror Turn Signal Lamp L131 or the entire Front Passengers Exterior Mirror Turn Signal Lamp L132 must be replaced.
Turn Signals and Entry Lamps in Exterior Mirrors Page 3 / 5 Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove Drivers Exterior Mirror Turn Signal Lamp L131 or the Front Passengers Exterior Mirror Turn Signal Lamp L132 Repair Manual, Body Exterior, Repair Group 66, Rear view mirror; removing and installing side turn signals. Installing: - Install Drivers Exterior Mirror Turn Signal Lamp L131 or Front Passengers Exterior Mirror Turn Signal Lamp L132 Repair Manual, Body Exterior, Repair Group 66, Rear view mirror; removing and installing side turn signals. Drivers Exterior Mirror Turn Signal Lamp L131 as well as Front Passengers Exterior Mirror Turn Signal Lamp L132 is installed in housing of left and right exterior mirror. Entry Lamps (in outside mirror) W52 / W53, removing and installing Drivers Entry Lamp (in outside mirror) W52 as well as Front Passengers Entry Lamp (in outside mirror) W53 are integrated into the exterior mirror housing mounting. Exterior mirror housing mounting must not be disassembled to remove and install entry lamps Removal and installation of both drivers and front passengers entry lamps is identical. Removing:
Turn Signals and Entry Lamps in Exterior Mirrors Page 4 / 5 Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Fold exterior mirror - 1 - in direction of - arrow - toward front. - Remove screw - 1 -. - Unclip entry light in direction of - arrow - from mounting and pull out as far as electrical cable length permits.
Turn Signals and Entry Lamps in Exterior Mirrors Page 5 / 5 - Pull bulb holder - 2 - in direction of - arrow - from housing - 1 -. Bulb, replacing: - Pull bulb - 1 - in direction of - arrow - from bulb holder - 2 -. Bulb: 12 V, W6 W Installing: Install in reverse order of removal, noting the following: After installation, perform functional test of exterior mirror lamp.
Front Side Marker Lamps Page 1 / 3 94-6 Front Side Marker Lamps Front Side Marker Lamps M11, removing and installing Special tools, testers and auxiliary items required Trim removal wedge 3409 Removal and installation of both front side marker lamps is identical. Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. When removing switches, trim, covers or displays, prevent damage to visible areas always applying appropriate tape to area surrounding the component, and the tools being used (screwdrivers, wedges etc.).
Front Side Marker Lamps Page 2 / 3 - Carefully press side marker lamp housing - 1 - into bumper trim (0.5-1.0 cm) - arrow -. - Release housing from retainer by positioning trim removal wedge VAS 3409 at rear edge - arrow A - and carefully pushing housing - 1 - forward - arrow B-. - Remove housing - 1 - in direction of - arrow - from bumper cover.
Front Side Marker Lamps Page 3 / 3 - Remove bulb holder with bulb - 1 - from housing. - Remove bulb from bulb holder. Bulb 12 V, 5 W Installing: - Insert bulb in bulb holder. - Ensure markings align and insert bulb holder - 1 - into housing. - First insert front edge of housing into bumper cover opening and then engage rear edge. - Check bulb function.
Rear Lights Page 1 / 17 94-7 Rear Lights General information Rear light arrays containing parking, turn signal, and brake lamps are located in each rear fender. An additional rear light array located in the rear lid contains back-up lamps. Before troubleshooting or servicing, technicians must be familiar with the functions and operation specifics of the standard or optional rear lighting system. Always read the owners manual and review applicable system functions. Additional information: Owners Manual Self Study Program - Course Number 892503 "VW 2006 GTI Introduction" Wiring Diagrams Component Locations Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. On Board Diagnostic, functions Rear light 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 light system malfunctions by performing OBD program using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding". Rear lights, checking with Output Diagnostic Test Mode (DTM) Rear light function can be checked via output Diagnostic
Rear Lights Page 2 / 17 Test Mode (DTM) of Vehicle Electrical System Control Module J519. - Connect Vehicle Diagnostic, Testing and Information System VAS 5051/5052 97-1, VAS 5051 / 5052 - 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" - Search and select appropriate light or switch component from menu, or - Select "2 - Output Diagnostic Test Mode (DTM) for all actuators" - Follow tester prompts Rear lights in rear fender through 10. 05, assembly Tightening torques tightening torques: 94-12, Rear lights in rear fender,
Rear Lights Page 3 / 17 1 - Nuts (inner view) 2 - Bulb holder Removing and installing 94-7, Rear lights in rear fender - bulb holder, removing and installing 3 - Left Taillamp M4 and Right Taillamp M2 12 V, P 21 W 4 - Rear light housing Removing and installing 94-7, Rear lights in rear fender, removing and installing 5 - Left Rear Turn Signal Lamp M6 and Right Rear Turn Signal Lamp M8 12 V, H 6 W
Rear Lights Page 4 / 17 6 - Left Brake Lamp M9 and Right Brake Lamp M10 12 V, P 21 W 7 - Rear light housing threaded studs (inner view) 8 - Electrical connection (inner view) 9 - Rear light housing threaded studs (inner view) Rear lights in rear fender from 11.05, assembly Tightening torques tightening torques: 94-12, Rear lights in rear fender, 1 - Nuts (inner view) 2 - Bulb holder
Rear Lights Page 5 / 17 Removing and installing 94-7, Rear lights in rear fender - bulb holder, removing and installing 3 - Left Taillamp M4 and Right Taillamp M2 12 V, P 21 W 4 - Rear light housing Removing and installing 94-7, Rear lights in rear fender, removing and installing Adjusting 94-7, Rear lights in rear fender from 11.05, adjusting 5 - Left Rear Turn Signal Lamp M6 and Right Rear Turn Signal Lamp M8 12 V, H 6 W 6 - Left Brake Lamp M9 and Right Brake Lamp M10 12 V, P 21 W 7 - Rear light adjuster Removing and installing 94-7, Rear light adjuster, removing and installing Adjusting 94-7, Rear lights in rear fender from 11.05, adjusting 8 - Rear light housing threaded studs (inner view) 9 - Electrical connection (inner view) 10 - Rear light housing threaded studs (inner view) Rear lights in rear fender, removing and installing Removing: Caution! Switch off all electrical consumers.
Rear Lights Page 6 / 17 Switch ignition off and remove ignition key. - Open rear lid and fold aside luggage compartment trim - 1 - in direction of - arrow -. - Release connection lock - 1 - in direction of - arrow - and disconnect electrical connection - 2-. - Remove nuts - 1 -. - Remove rear light assembly. Installing: Install in reverse order of removal, noting the following:
Rear Lights Page 7 / 17 - Install and tighten nuts - 1 - to specified tightening torque 94-12, Rear lights in rear fender, tightening torques:. Electrical connection to rear light assembly must engage "audibly" when connecting. - Check alignment of rear light assembly relative to bumper cover. - On vehicles through 10.05 production, alignment of rear light assembly to bumper cover is not possible. - On vehicles from 11.05 production, check and align rear light assembly relative to bumper cover 94-7, Rear lights in rear fender from 11.05, adjusting Rear lights in rear fender through 10.05, replacing Special tools, testers and auxiliary items required Torque Screwdriver VAG 1624 (or locally available equivalent)
Rear Lights Page 8 / 17 Replacement rear light assemblies may or may not be available as originally installed in production. As a result, it may be necessary to install replacement rear light housing using a non-adjustable adapter that ensures proper fit between the body and the rear light (adapter takes up space due to different housing configuration). In these cases, use the following procedure: - Remove rear light 94-7, Rear lights in rear fender, removing and installing. - Adapter mounts to area indicated by - arrow-. - Install adapter - 2 - to replacement rear light housing - 1 - as illustrated. - Install and tighten screw - 3 - to specified tightening torque 94-12, Rear lights in rear fender, tightening torques:. - Install rear light 94-7, Rear lights in rear fender, removing and installing. Rear lights in rear fender from 11.05, replacing - Rear lights in rear fender, removing and installing 94-7, Rear lights in rear fender, removing and installing.
Rear Lights Page 9 / 17 Rear lights in rear fender from 11.05, adjusting Rear lights from 11.05 production include an adjuster that enables even alignment of rear light housing relative to the bumper cover. - Should rear light to bumper cover alignment not be flush as indicated - arrow -, an adjustment of +/- 2 mm inward or outward is possible using the adjuster. - Open rear lid and fold aside luggage compartment trim - 1 - in direction of - arrow -.
Rear Lights Page 10 / 17 - Loosen nuts - 1 - (do not remove). - Turn adjuster - arrow - in direction needed to bring rear light in alignment with bumper cover as illustrated above. - Tighten nuts - 1 - to specified tightening torque 94-12, Rear lights in rear fender, tightening torques:. Rear light adjuster, removing and installing Rear lights from 11.05 production include an adjuster that enables even alignment of rear light housing relative to the bumper cover.
Rear Lights Page 11 / 17 Removing: - Remove rear light 94-7, Rear lights in rear fender, removing and installing. - Depress locking clips - arrow A - on adjuster - 1 - and press in direction of - arrow B - from rear body sheet metal. Installing: - Use SW10 socket to insert adjuster - 2 - into rear body sheet metal - 1 - in direction of - arrow - until it engages. Rear lights in rear fender - bulb holder, removing and installing Removing: - Remove rear light assembly 94-7, Rear lights in rear fender, removing and installing.
Rear Lights Page 12 / 17 - Release retaining tabs - 1 -, - 3 - and - 4 - each in direction of - arrow - and remove bulb holder - 2-. Installing: Install in reverse order of removal. Rear lights in rear lid, assembly Tightening torques 94-12, Rear light housing in rear lid, tightening torques:
Rear Lights Page 13 / 17 1 - Nuts (inner view) 2 - Bulb holder (inner view) Removing and installing 94-7, Rear lights in rear lid - bulb holder, removing and installing 3 - Bulb 12 V, P 21 W Left Back-Up Lamp M16 or Right Back-Up Lamp M17 4 - Rear light housing Removing and installing 94-7, Rear lights in rear lid, removing and installing 5 - Washer A6.5 x 14 x 1.6
Rear Lights Page 14 / 17 6 - Rear light housing threaded studs (inner view) Rear lights in rear lid, removing and installing Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Open rear lid and remove cover - 1 - in direction of - arrow -. - Disconnect electrical connection - 1 - in direction of - arrow -. - Remove lower rear lid trim. Repair Manual, Body Interior, Repair Group 70,
Rear Lights Page 15 / 17 - Remove nuts - 1 -. - Remove rear light housing. Installing: Install in reverse order of removal, noting the following: To prevent washer from falling into body during installation, secure washer - 2 - to threaded stud - 1 - with adhesive before installing. - Insert washers - 2 - onto threaded stud - 1-. - Insert rear light assembly to opening in rear lid
Rear Lights Page 16 / 17 - Install and tighten nuts - 1 - to specified tightening torque 94-12, Rear light housing in rear lid, tightening torques:. - Check gap dimension to body after installing rear lamp assembly. Rear lights in rear lid - bulb holder, removing and installing Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Open rear lid and remove cover - 1 - in direction of - arrow -.
Rear Lights Page 17 / 17 - Disconnect electrical connection - 1 - in direction of - arrow -. While shown as removed in the following illustration, it is not necessary to remove lower rear lid trim. - Turn bulb holder - 1 - in direction of - arrow - and remove from rear light housing. Installing: Install in reverse order of removal.
License Pate Lights Page 1 / 3 94-8 License Pate Lights General information License plate lights are located in rear lid. Additional information: Owners Manual Self Study Program - Course Number 892503 "VW 2006 GTI Introduction" Wiring Diagrams Component Locations On Board Diagnostic, functions License plate light 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 license plate light system malfunctions by performing OBD program using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding". License plate lights, checking with Output Diagnostic Test Mode (DTM) License plate light function can be checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module J519. - Connect Vehicle Diagnostic, Testing and Information System VAS 5051/5052 97-1, VAS 5051 / 5052 - 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)"
License Pate Lights Page 2 / 3 - 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" - Search and select appropriate light or switch component from menu, or - Select "2 - Output Diagnostic Test Mode (DTM) for all actuators" - Follow tester prompts License Plate Lamps X4 / X5, removing and installing Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove screws - arrows -. - Remove diffusion lens with License Plate Light X. License Plate Light X : bulb 12 V, C 5 W
License Pate Lights Page 3 / 3 Installing: Install in reverse order of removal.
High-Mount Brake Light Page 1 / 3 94-9 High-Mount Brake Light High-mount Brake Light M25 - Rabbit, removing and installing The high-mount brake light assembly consists of several arrays of Light Emitting Diodes (LEDs) which cannot be serviced or replaced separately. Should individual LEDs or LED arrays be damaged or malfunction, replace entire brake light assembly. Special tools, testers and auxiliary items required Plastic wedge T10039/1 (or locally available equivalent) Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Apply adhesive tape to upper rear lid at brake light to avoid paint damage. Caution! When removing high-mount brake light, ensure seal is not damaged.
High-Mount Brake Light Page 2 / 3 - Place plastic wedge T10039/1 between brake light and spoiler as illustrated. Using light blows with flat hand, drive wedge between brake light and spoiler and remove brake light from rear lid. In the event brake light cannot be removed as described, contact VW Technicians Helpline. - Disconnect electrical connection - arrow -. Installing: Install in reverse order of removal, noting the following: When installing brake light, ensure seal is seated correctly. Seal must not be warped or damaged. High-mount Brake Light M25 - GTI, removing and installing The high-mount brake light assembly consists of
High-Mount Brake Light Page 3 / 3 several arrays of Light Emitting Diodes (LEDs) which cannot be serviced or replaced separately. Should individual LEDs or LED arrays be damaged or malfunction, replace entire brake light assembly. Removing: Caution! Switch off all electrical consumers. Switch ignition off and remove ignition key. - Remove roof edge spoiler. Repair Manual, Body Exterior, Repair Group 66, - Remove both screws - 2 - on inside of roof edge spoiler. - Release catch - 1 - and remove brake light toward rear from roof edge spoiler. Installing: Install in reverse order of removal, noting the following: When installing roof edge spoiler, ensure rubber seal between brake light wiring harness and body is seated correctly.
Steering Column Switches Page 1 / 16 94-10 Steering Column Switches General information The function of the steering column switches are integrated with the Steering Column Electronic Systems Control Module J527. Additional information: Owners Manual Self Study Program - Course Number 892503 "VW 2006 GTI Introduction" Wiring Diagrams Component Locations On Board Diagnostic, functions The Steering Column Electronic Systems Control Module J527 is controlled by an internal microprocessor with On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory. Troubleshoot steering column switch system malfunctions by performing OBD program using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding". After installing a new Steering Column Electronic Systems Control Module J527, it must be coded 94-10, Steering Column Electronic Systems Control Module J527 On Board Diagnostic (OBD), functions. If malfunctions occur at steering column switch, coding of Steering Column Electronic Systems Control Module J527 must be checked 94-10, Steering Column Electronic Systems Control Module J527 On Board Diagnostic (OBD), functions. Steering column switches, assembly
Steering Column Switches Page 2 / 16 1 - Turn signal switch assembly Switch assembly consists of Turn Signal Switch E2, Headlamp Dimmer/Flasher Switch E4 and Cruise Control Switch E45 Switch is illustrated without Cruise Control Switch E45 Removing and installing 94-10, Turn signal switch assembly, removing and installing 2 - Mounting frame Removing and installing 94-10, Mounting frame, removing and installing 3 - Windshield Wiper Switch E
Steering Column Switches Page 3 / 16 Removing and installing 94-10, Windshield Wiper Switch E, removing and installing 4 - Screw 5 - Steering Column Electronic Systems Control Module J527 Removing and installing 94-10, Steering Column Electronic Systems Control Module J527, removing and installing Coding 94-10, Steering Column Electronic Systems Control Module J527 On Board Diagnostic (OBD), functions Output Diagnostic Test Mode (DTM) 94-10, Steering Column Electronic Systems Control Module J527, Output Diagnostic Test Mode (DTM) 6 - Airbag Spiral Spring/Return Spring With Slip Ring F138 Removing and installing 94-10, Airbag Spiral Spring/Return Spring With Slip Ring F138, removing and installing 7 - Steering Angle Sensor G85 Removing and installing 94-10, Steering Angle Sensor G85, removing and installing Basic setting 94-10, Steering Angle Sensor G85 On Board Diagnostic (OBD), functions Steering column switches, removing and installing 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.
Steering Column Switches Page 4 / 16 When removing steering column switches and drilling shear bolts, ensure that no metal shavings enter steering column switches. Removing: Warning! Special safety precautions apply to vehicles equipped with airbags. Heed all WARNINGS pertaining to airbag servicing Repair Manual, Body Interior, Repair Group 69, Airbag; removing and installing steering wheel When removing the complete steering column switch assembly with mounting frame, it is disassembled and steering lock housing is also removed with it. New shear bolts are required for installing steering lock housing. Also, if only one individual component of steering column switch is removed or replaced, the sequence described as follows must always be adhered to. - Disconnect battery 27-4, Battery, disconnecting and connecting. - Remove steering wheel Repair Manual, Body Interior, Repair Group 69, Airbag; removing and installing; Removing. - Remove steering column trim Repair Manual, Body Interior, Repair Group 68, storage compartments, covers and panels; removing and installing steering column trim. Remove components of steering column switches in the following sequence: Steering Column Electronic Systems Control Module
Steering Column Switches Page 5 / 16 J527 94-10, Steering Column Electronic Systems Control Module J527, removing and installing Airbag Spiral Spring/Return Spring With Slip Ring F138 94-10, Airbag Spiral Spring/Return Spring With Slip Ring F138, removing and installing Steering Angle Sensor G85 94-10, Steering Angle Sensor G85, removing and installing Turn signal switch 94-10, Turn signal switch assembly, removing and installing Windshield Wiper Switch E 94-10, Windshield Wiper Switch E, removing and installing Mounting frame 94-10, Mounting frame, removing and installing Installing: Install in reverse order of removal. Steering Column Electronic Systems Control Module J527, removing and installing After installing a new control module, it must be coded 94-10, Steering Column Electronic Systems Control Module J527 On Board Diagnostic (OBD), functions. If malfunctions occur at steering column switch, coding of control module must be checked 94-10, Steering Column Electronic Systems Control Module J527 On Board Diagnostic (OBD), functions. Removing:
Steering Column Switches Page 6 / 16 - Remove screw - 1 -. Caution! DO NOT attempt to remove control module without releasing center retaining clip as described in next step. Damage to control module will result. - Insert a wire, small screwdriver or drill with 2.5 mm as illustrated - 2 - approx. 45 mm into hole - arrow 1 - in order to release center retaining clip - arrow 2 -. It may be necessary to twist the tool slightly in order to release clip. Only after center retaining clip has been released: - Use a small screwdriver to depress rear retaining clip as illustrated - arrow A -. - Carefully pull Steering Column Electronic Systems Control Module J527 downward from steering column switches.
Steering Column Switches Page 7 / 16 When removing, ensure module is removed straight downward without tilting. - Disengage lock - arrow A - on electrical connection - 1 - and disconnect. - Disengage lock - 3 - on electrical connection - 2-. - Disengage lock - arrow B - on electrical connection - 2 - and disconnect. Installing: Install in reverse order of removal, noting the following: Ensure that no electrical pins are bent and that the connections engage audibly when reconnecting. Airbag Spiral Spring/Return Spring With Slip Ring F138, removing and installing Removing: When removing, the spiral spring must not be twisted from the center position and wheels must be in the "straight ahead position".
Steering Column Switches Page 8 / 16 - Release clips - arrows - slightly at spiral spring - 1 - and remove spiral spring toward rear from steering column and steering column switches. Installing: Install in reverse order of removal, noting the following: When installing spiral spring, spiral spring must be in center position and wheels must be in the "straight ahead position". The following depicts center position of spiral spring, which is dependent on the manufacturer: The color marked (black square) band - arrow - must be located in viewing window - 1 -.
Steering Column Switches Page 9 / 16 The color marked (yellow) band - arrow - must be located in viewing window - 1 -. If a new Steering Angle Sensor G85 is installed, then the "Basic Setting" must be performed 94-10, Steering Angle Sensor G85 On Board Diagnostic (OBD), functions. Steering Angle Sensor G85, removing and installing Removing: - Remove Steering Angle Sensor G85-1 - toward rear from steering column switches - arrow -. Installing: Install in reverse order of removal, noting the following: If a new Steering Angle Sensor G85 is installed, then the "Basic Setting" must be performed 94-10, Steering Angle Sensor G85 On Board Diagnostic (OBD), functions.
Steering Column Switches Page 10 / 16 Turn signal switch assembly, removing and installing The turn signal switch assembly consists of components Turn Signal switch E2, Headlamp Dimmer/Flasher Switch E4 and Cruise Control Switch E45. For reasons of clarity, steering column switch assembly is shown removed in the illustration. Removing: - Release retaining clips - arrows - using a 1.0 mm feeler gauge - 1 - and remove "turn signal switch" toward rear. Installing: Install in reverse order of removal, noting the following: "Turn signal switch" must engage audibly. Windshield Wiper Switch E, removing and installing Removing:
Steering Column Switches Page 11 / 16 For reasons of clarity, steering column switches are depicted as removed in the illustration. - Release retaining clips - arrows - using a 1.0 mm feeler gauge - 1 - and remove Windshield Wiper Switch E toward rear. Installing: Install in reverse order of removal, noting the following: Windshield Wiper Switch E must engage audibly. Mounting frame, removing and installing In order to remove the mounting frame for steering column switches - 2 -, shear bolts of steering lock
Steering Column Switches Page 12 / 16 housing must be drilled out. New shear bolts - 1 - are required for the subsequent installation Parts Catalog. Caution! Before drilling out shear bolts, ensure all components/switches secured to mounting frame are removed beforehand. When drilling shear bolts, ensure drill shavings do not affect neighboring components. Damage and / or malfunctions will result. Follow the specified sequence when removing components. 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. When removing steering column switches and drilling shear bolts, ensure that no metal shavings enter steering column switches. Removing: - Disconnect battery 27-4, Battery, disconnecting and connecting. Remove the following components in order: - Remove steering wheel Repair Manual, Body Interior, Repair Group 69, Airbag; removing and installing; Removing. - Remove steering column trim
Steering Column Switches Page 13 / 16 Repair Manual, Body Interior, Repair Group 68, storage compartments, covers and panels; removing and installing steering column trim. - Remove Steering Column Electronic Systems Control Module J527 94-10, Steering Column Electronic Systems Control Module J527, removing and installing. - Remove Airbag Spiral Spring/Return Spring With Slip Ring F138 94-10, Airbag Spiral Spring/Return Spring With Slip Ring F138, removing and installing. - Remove Steering Angle Sensor G85 94-10, Steering Angle Sensor G85, removing and installing. - Remove Turn Signal switch E2 94-10, Turn signal switch assembly, removing and installing. - Remove Windshield Wiper Switch E 94-10, Windshield Wiper Switch E, removing and installing. - Disconnect electrical connection - arrow - at induction coil - 3 -. After components secured to mounting frame have been removed, the mounting frame can be removed: - Drill out screws - 1 - for steering lock housing - 3-. Bolts M8-1 -, core hole diameter 6.8 mm. - Remove steering lock housing and mounting frame - 2 - from steering column toward rear. - Remove steering lock housing from mounting frame. Installing: - Set steering lock housing in mounting frame.
Steering Column Switches Page 14 / 16 - Slide mounting frame - 2 - as far as possible onto steering column. - Connect electrical connection - arrow - to induction coil - 3 -. - Bolt steering lock housing to steering column with new shear bolts - 1 -. - Tighten shear bolts - 1 - until bolt heads shear off. - Install remaining components in reverse order of removal. Steering Column Electronic Systems Control Module J527 On Board Diagnostic (OBD), functions Removing and installing Steering Column Electronic Systems Control Module J527 94-10, Steering Column Electronic Systems Control Module J527, removing and installing Steering Column Electronic Systems Control Module J527, coding - Connect Vehicle Diagnostic, Testing and Information System VAS 5051/5052 97-1, VAS 5051 / 5052 - 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)"
Steering Column Switches Page 15 / 16 - Select "01 - Self-diagnosis" - Select "16- Steering wheel electronics" - Select "Steering wheel electronics functions" - Select "Coding control module steering wheel electronics" - Follow tester prompts Steering Column Electronic Systems Control Module J527, Output Diagnostic Test Mode (DTM) - Connect Vehicle Diagnostic, Testing and Information System VAS 5051/5052 97-1, VAS 5051 / 5052 - 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 "16- Steering wheel electronics" - Select "Steering wheel electronics functions" - Select "Steering wheel electronics Diagnostic Test Mode (DTM)" - Follow tester prompts. Steering Angle Sensor G85 On Board Diagnostic (OBD), functions Steering Angle Sensor G85, removing and installing 94-10, Steering Angle Sensor G85, removing and installing Steering Angle Sensor G85, Basic Setting - Connect Vehicle Diagnostic, Testing and Information System VAS 5051/5052 97-1, VAS 5051 / 5052 - Select operating mode "Guided Fault Finding"
Steering Column Switches Page 16 / 16 - 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 "Suspension (Repair Group 01; 40-49)" - Select "Brake system" - Select "On Board Diagnostic capable systems Mark 60 / Mark 70" - Select "Functions" - Select "Basic setting steering angle sensor G85" - Follow tester prompts.
Ignition/Starter Switch and Lock Cylinder Page 1 / 8 94-11 Ignition/Starter Switch and Lock Cylinder Steering lock housing, removing and installing 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. When removing steering column switches and drilling shear bolts, ensure that no metal shavings enter steering column switches. Steering lock may be destroyed. If steering lock is operated without lock cylinder, it locks and must be replaced. Steering lock must not be operated without lock cylinder. Warning! Special safety precautions apply to vehicles equipped with airbags. Heed all WARNINGS pertaining to airbag servicing Repair Manual, Body Interior, Repair Group 69, Airbag; removing and installing steering wheel To remove steering lock housing, it is first necessary to remove mounting frame for steering column switches. Removing: - Disconnect battery 27-4, Battery, disconnecting and connecting.
Ignition/Starter Switch and Lock Cylinder Page 2 / 8 - Remove mounting frame for steering column switches 94-10, Mounting frame, removing and installing Lock cylinder, removing and installing 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. When removing steering column switches and drilling shear bolts, ensure that no metal shavings enter steering column switches. Steering lock may be destroyed. If steering lock is operated without lock cylinder, it locks and must be replaced. Steering lock must not be operated without lock cylinder. Warning! Special safety precautions apply to vehicles equipped with airbags. Heed all WARNINGS pertaining to airbag servicing Repair Manual, Body Interior, Repair Group 69, Airbag; removing and installing steering wheel Removing: - Disconnect battery 27-4, Battery, disconnecting and connecting. - Remove steering wheel Repair Manual, Body Interior, Repair Group 69, Airbag; removing and installing; Removing
Ignition/Starter Switch and Lock Cylinder Page 3 / 8. - Remove steering column trim Repair Manual, Body Interior, Repair Group 68, storage compartments, covers and panels; removing and installing steering column trim. - Remove Steering Column Electronic Systems Control Module J527 94-10, Steering Column Electronic Systems Control Module J527, removing and installing. - Remove Airbag Spiral Spring/Return Spring With Slip Ring F138 94-10, Airbag Spiral Spring/Return Spring With Slip Ring F138, removing and installing. - Remove Steering Angle Sensor G85 94-10, Steering Angle Sensor G85, removing and installing. For reasons of clarity, illustration does not show turn signal switch and windshield wiper switch. Switches must not be removed when removing lock cylinder. Induction coil for anti-theft immobilizer is integrated with lock cylinder and cannot be serviced separately. - Insert ignition key into lock cylinder and turn it into
Ignition/Starter Switch and Lock Cylinder Page 4 / 8 position "Run". Lock cylinder - key positions: 1 - Position Off 2 - Position Run 3 - Position Start For reasons of clarity, the following illustration depicts lock cylinder as removed and without ignition key. - Insert a steel wire (approx. 1.2 mm) into the hole - arrow - next to the ignition key. - Using steel wire - 2 -, release - arrow - lock cylinder retainer - 3 -. - Remove lock cylinder - 1 - from steering lock housing.
Ignition/Starter Switch and Lock Cylinder Page 5 / 8 - Disconnect electrical connection - arrow - at induction coil. Installing: To improve clarity, the ignition key is not shown in the following illustration. - Insert ignition key into lock cylinder - 1 - and turn it to the "Run" position. - Using steel wire - 2 -, to release - arrow - lock cylinder retainer - 3 -. - Insert lock cylinder - 1 - into steering lock housing. Connection of induction coil for anti-theft immobilizer must be inserted into guide on steering lock housing. - Pull steel wire - 2 - from lock cylinder - 1 - and verify lock cylinder is securely seated in the steering lock housing. - Connect the immobilizer induction coil electrical connection. - Install all remaining components in reverse order of removal.
Ignition/Starter Switch and Lock Cylinder Page 6 / 8 Ignition/Starter Switch, removing and installing 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. Removing: - Disconnect battery 27-4, Battery, disconnecting and connecting. - Remove steering wheel Repair Manual, Body Interior, Repair Group 69, Airbag; removing and installing; Removing. - Remove steering column trim Repair Manual, Body Interior, Repair Group 68, storage compartments, covers and panels; removing and installing steering column trim. - Disconnect electrical connection - 2 - from ignition/starter switch - 1 -. - Release ignition/starter switch using a small screwdriver - arrows -. - Pull out ignition/starter switch - 1 - from steering lock
Ignition/Starter Switch and Lock Cylinder Page 7 / 8 housing. Installing: - Insert ignition/starter switch into steering lock housing until it engages audibly. - Insert ignition key into lock cylinder and turn it into position "Run". Key must be located in "Run" position. Lock cylinder - key positions: 1 - Position Off 2 - Position Run 3 - Position Start - Install all remaining components in reverse order of removal. Ignition Key Removal Lock Solenoid N376, removing and installing Ignition Key Removal Lock Solenoid N376 is installed next to the ignition/starter switch. To remove ignition key in vehicles with automatic transmission, always shift selector lever into position "P" and then switch off ignition. Otherwise, Ignition
Ignition/Starter Switch and Lock Cylinder Page 8 / 8 Key Removal Lock Solenoid N376 prevents ignition key from being removed. Removing: - Remove Steering Column Electronic Systems Control Module J527 94-10, Steering Column Electronic Systems Control Module J527, removing and installing. - Release lock - 2 - using a suitable screwdriver. - Pull Ignition Key Removal Lock Solenoid N376-1 - in direction of - arrow - from mounting. - The electrical connection is automatically disconnected upon removal. Installing: - Install in reverse order of removal, noting the following: After connecting battery, perform output Diagnostic Test Mode (DTM) to activate Ignition Key Removal Lock Solenoid N376 94-10, Steering Column Electronic Systems Control Module J527, Output Diagnostic Test Mode (DTM).
Lights, Switches - Exterior, tightening torques Page 1 / 1 94-12 Lights, Switches - Exterior, tightening torques Headlamps, tightening torques Fastener / location Tightening torques Top headlamp / screw 4 Nm Left lower headlamp / screw 4 Nm Right lower headlamp / screw 4 Nm Fog lamps, tightening torques: Fastener / location Tightening torques Fog lamp / screws 1.5 Nm Rear lights in rear fender, tightening torques: Fastener / location Tightening torques Rear light housing / nuts 3.0 Nm Adjustment adapter / screw 0.6 Nm 0.2 Nm Rear light housing in rear lid, tightening torques: Fastener / location Tightening torques Rear light housing / nuts 3.5 Nm 0.5 Nm Vehicle level sensors, tightening torques: Fastener / location Tightening torques Left Front Level Control System Sensor G78 / bolts M6 9 Nm Left Rear Level Control System Sensor G76 / bolts M5 5 Nm