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Workshop Manual
Transporter 1991 ➤

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Transporter 1996 ➤
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Electrical system

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Edition 10.2004

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Service Department. Technical Information

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27 - Starter, current supply, CCS

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92 - Windscreen wash/wipe system

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94 - Lights, bulbs, switches - exterior
96 - Lights, bulbs, switches - interior

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97 - Wiring
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2015 Volkswagen AG, Wolfsburg 00052705920

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Contents

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27 - Starter, current supply, CCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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1.1 Fundamentals for batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Types of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Warning notices and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Battery terminal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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2 Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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2.1 Procedure when checking a battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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2.3 Checking battery with magic eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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2.4 Checking low maintenance battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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2.5 Checking no load voltage of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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2.6 Battery tester with printer VAS 5097 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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2.7 Evaluating test result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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3 Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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3.1 Battery charger VAS 5095 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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3.2 Battery charger VAS 5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.3 Totally discharged batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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4 Disconnecting and reconnecting batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 Disconnecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2 Connecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5 Removing and installing battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.1 Battery in engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2 Second battery under driver seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6 Torque settings: battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1 Removing and installing starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8 Torque settings: starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9 Alternator with V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.1 4-cylinder petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.2 4-cylinder diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.3 Checking and adjusting V-belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10 Alternator with poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.1 4-cylinder engine with 90 A alternator ▸ 04.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.2 4-cylinder engine with 90 A alternator 05.99 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
10.3 4-cylinder engine with 120 A alternator ▸ 04.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10.4 4-cylinder engine with 120 A alternator 05.99 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.5 4-cylinder engine with air conditioner compressor or 2nd alternator ▸ 04.99 . . . . . . . . . . 73
10.6 4-cylinder engine with air conditioner compressor or 2nd alternator 05.99 ▸ . . . . . . . . . . . . 79
10.7 5-cylinder engine without air conditioner or 2nd alternator ▸ 04.99 . . . . . . . . . . . . . . . . . . 85
10.8 5-cylinder engine without air conditioner or 2nd alternator 05.99 ▸ . . . . . . . . . . . . . . . . . . 88
10.9 5-cylinder engines with air conditioner or 2nd alternator or hydraulic pump ▸ 04.99 . . . . . . 90
10.10 5-cylinder engines with air conditioner or 2nd alternator or hydraulic pump 05.99 ▸ . . . . . . 93
10.11 6-cylinder fuel injection engine ▸ 04.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.12 6-cylinder fuel injection engine 05.99 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.13 Compact alternator with poly V-belt drive ▸ 04.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
10.14 Compact alternator with poly V-belt drive 05.99 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
10.15 Renewing poly V-belt pulley without freewheel on alternator . . . . . . . . . . . . . . . . . . . . . . . . 106
10.16 Renewing poly V-belt with freewheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
11 Repairing alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
11.1 65 A - Valeo version with poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

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 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

11.2 90 A - Bosch version with poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

11.3 70 A, 90 A and 120 A alternator with poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
12 Alternator torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
12.1 General torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
12.2 Torque settings: alternator with V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
12.3 4-cylinder engine with 90 A alternator ▸ 04.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
12.4 4-cylinder engine with 90 A alternator 05.99 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
12.5 4-cylinder engine with 120 A alternator ▸ 04.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
12.6 4-cylinder engine with 120 A alternator 05.99 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
12.7 4-cylinder engine with air conditioner compressor or 2nd alternator ▸ 04.99 . . . . . . . . . . 121
12.8 4-cylinder engine with air conditioner compressor or 2nd alternator 05.99 ▸ . . . . . . . . . . . . 122
12.9 5-cylinder engine without air conditioner or 2nd alternator ▸ 04.99 . . . . . . . . . . . . . . . . . . 122
12.10 5-cylinder engine without air conditioner or 2nd alternator 05.99 ▸ . . . . . . . . . . . . . . . . . . 122
12.11 5-cylinder engine with air conditioner or 2nd alternator or hydraulic pump ▸ 04.99 . . . . . . 122
12.12 5-cylinder engine with air conditioner or 2nd alternator or hydraulic pump 05.99 ▸ . . . . . . 122
12.13 6-cylinder fuel injection engine ▸ 04.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
12.14 6-cylinder fuel injection engine 05.99 ▸age.n.A.G.. V. o.lk.s.w.ag. e.n.A.G. d.o. . . . . . . . . . . . . . . . . . . . . . . . . 123
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13 Cruise control system (CCS) d.by. V.o. . . . . . . . . . . . . . . . . . . . . . .ot. g.u.a . . . . . . . . . . . . . . . . . . . 124
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13.3 Adjusting positioning element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

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13.4 Removing positioning element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

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13.5 Removing and installing vent valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
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13.6 Removing and installing cruise control system (CCS) vacuum pump V18 . . . . . . . . . . . . 127
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13.7 Removing and installing cruise control system (CCS) control unit J213 . . . . . . . . . . . . . . 127

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13.8 Checking vacuum system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

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90 - Gauges, instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

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1 Dash panel insert ▸ 12.95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.1 Removing and installing dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.2 Assembly overview - dash panel insert with rev counter or analogue clock . . . . . . . . . . . . rrectne 129
1.3 Assembly overview - dash panel insert with multi-function indicator (MFI) . . . . . . . . . . . . 131
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1.4 Dismantling and assembling dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

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1.5 Pin assignment of connections on dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

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2 Dash panel insert 01.96 ▸07.98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

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2.1 Removing and installing dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

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2.2 Pin assignment of connections on dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

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3 Dash panel insert 08.98 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

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3.1 Warning with oil level too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

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3.2 Fault detection and fault display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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3.3 Removing and installing dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
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3.4 Dash panel insert, rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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3.5 Pin assignment of connections on dash panel insert with no data BUS connection . . . . . . 154
3.6 Pin assignment of connections at dash panel insert with data BUS connection . . . . . . . . 156
4 Service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4.2 Service interval display on dash panel inserts with no data BUS connection . . . . . . . . . . 159
4.3 Service interval display on dash panel inserts with data BUS connection . . . . . . . . . . . . . . 161
5 Tachograph ▸ 04.99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5.1 Pin assignment of the connections on the tachograph hood . . . . . . . . . . . . . . . . . . . . . . . . 164
5.2 Pin assignment of connections on tachograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
6 Tachograph 05.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
6.1 Pin assignment of connections on tachograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
6.2 Removing and installing tachograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

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 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

1 Windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.1 Assembly overview - windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.2 Setting park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.3 Adjusting wiper blade park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.4 Removing and installing wiper blade rubber insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2 Windscreen washer system (short front end) ▸ 12.95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
2.1 Assembly overview - windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
2.2 Removing and adjusting washer jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2.3 Hose connections at windscreen washer pump V5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3 Windscreen washer system (long front end) 01.96 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3.1 Assembly overview - windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3.2 Removing and adjusting washer jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3.3 Hose connections at windscreen washer pump V5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4 Rear window wiper and washer system (tailgate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
4.1 Assembly overview of rear window wipe/wash system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
4.2 Setting park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
4.3 Adjusting rear window wiper park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
4.4 Adjusting washer spray jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
5 Rear window wiper and washer olkssystem
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5.1 Assembly overview kswof
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5.2 Setting parkedposition
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5.3 Adjusting ut
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5.4 Adjusting
ss washer spray jet . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
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6 Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

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6.1 Assembly overview - headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

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erm

ab

6.2 Removing and installing spray jet assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

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6.3 Removing and installing pop-up spray jet cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

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6.4 Adjusting washer spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

hole

spec

7 Hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

es, in part or in w

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7.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

7.2 Repairing smooth pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
7.3 Repairing corrugated pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
rrectness of i

94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

l purpos

1 Headlights (short front end) ▸ 12.95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

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1.1 Assembly overview - headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

orm

1.2 Renewing headlight bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

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1.3 Removing and installing headlight insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

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1.4 Removing and installing left headlight range control motor V48 and right headlight range
thi
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control motor V49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

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1.5 Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

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2 Headlights (long front end) 01.96 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

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2.1 Assembly overview - headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
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2.2 Renewing headlight bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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2.3 Removing and installing headlight insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
cted
193
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Prote AG.
2.4 Removing and installing left headlight range control motor V48 and right headlight range
control motor V49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2.5 Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3 Front fog lights (short front end) ▸ 12.95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3.1 Removing and installing front fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3.2 Renewing front fog light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3.3 Adjusting fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4 Fog lights (long front end) 01.96 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Contents iii
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

4.1 Removing and installing fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

4.2 Renewing fog light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4.3 Adjusting fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
5 Front turn signal lamps (short front end) ▸ 12.95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
5.1 Removing and installing front turn signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
5.2 Renewing front left turn signal bulb M5 and front right turn signal bulb M7 . . . . . . . . . . . . 199
6 Front turn signal lamps (long front end) 01.96 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
6.1 Removing and installing front turn signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
6.2 Renewing front left turn signal bulb M5 and front right turn signal bulb M7 . . . . . . . . . . . . 200
7 Tail light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
7.1 Removing and installing van tail light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
7.2 Removing and installing drop-side tail light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
8 Additional brake light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
8.1 Removing and installing additional brake light bulb holder (rear lid) . . . . . . . . . . . . . . . . . . 203
8.2 Removing and installing additional brake light housing (rear lid) . . . . . . . . . . . . . . . . . . . . 203
9 Number plate lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
9.1 Removing number plate lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
10 Rear fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
10.1 Removing rear fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
11 Steering column switch and ignition/starter switch ▸08.98 . . . . . . . . . . . . . . . . . . . . . . . . . . 206
11.1 Assembly overview - steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
11.2 Removing and installing steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
11.3 Pin assignment on steering column switch and ignition/starter switch . . . . . . . . . . . . . . . . 209
11.4 Pin assignment at connector for multi-function indicator (MFI) and cruise control system
(CCS) (at steering lock housing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Volkswa
11.5 Removing and installing steering lock housing . . . . . . . . . .sw. a.g.en. A. G . .. . . . . . g.e.n .AG
. .do. e.s. . . . . 210
lk no
11.6 Removing and installing lock cylinder . . . . . . . . . . . d. b.y.V.o . . . . . . . . . . . . . . . . . . . . . . t.g.ua.r 212
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12 Steering column switch and ignition/starter switchth08.98 or ▸ . . . . . . . . . . . . . . . . . . . . . . . . 214 tee
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12.1 Assembly overview - steering column . . . . . .ss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 ac
a

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12.2 Removing and installing steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
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12.3 Removing and installing steering lock housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
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12.4 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

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12.5 Pin assignment on steering column switch and ignition/starter switch . . . . . . . . . . . . . . . . 217

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12.6 Pin assignment at connector for multi-function indicator (MFI) / rear window wiper and cruise

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control system (CCS) (at steering lock housing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

spec
es, in part or in w

96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

t to the co
1 Immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
1.1 Assembly overview - immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 rrectness of i
1.2 Immobilizer control unit J362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
l purpos

1.3 Removing and installing immobilizer reader coil D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

1.4 Transponder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
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1.5 Fuel shut-off valve control unit J366 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

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2 Interior lights and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

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2.1 Removing and installing light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

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2.2 Removing and installing headlight range control adjuster E102 . . . . . . . . . . . . . . . . . . . . 229
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2.3 Removing and installing switches in centre of dash panel ▸ 12.95 . . . . . . . . . . . . . . . . . . 229
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2.4 Removing and installing switches in centre of dash panel 01.96 ▸ . . . . . . . . . . . . . . . . . . 230
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97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
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1 Relay plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
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1.1 Removing and installing relay plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
AG.

1.2 Removing and installing multi-pin connector on back of relay plate . . . . . . . . . . . . . . . . . . 232
2 Wiring harness and connector repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

iv Contents
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

2.1 Safety remarks: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

2.2 General notes concerning repairs to vehicle electrical system . . . . . . . . . . . . . . . . . . . . . . 234
2.3 Remarks concerning wiring harness and connector repairs . . . . . . . . . . . . . . . . . . . . . . . . 234
2.4 Supplementary notes on repair of CAN bus wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.5 Wiring harness repair set VAS 1978 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
3 Renewal of aerial wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
3.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
3.2 Assembly overview - an aerial wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
3.3 Installing a new aerial wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

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Contents v
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004
AG. Volkswagen AG d
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vi Contents
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

27 – Starter, current supply, CCS

1 Battery

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !
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Caution utho eo
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To prevent damage to the battery and vehicle, the following

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should be observed concerning types of battery ⇒ page 1 .

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1.1 Fundamentals for batteries

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To ensure long use of the battery, the battery must be checked,
es, in part or in w

serviced and maintained according to the instructions in this man‐

t to the co
ual.
Apart from supplying energy for starting the engine, the battery

rrectness of i
has other tasks: it acts as a buffer and supplies electrical energy
to the complete vehicle electrical system.
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Note
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Refer to ⇒ Self-study programme No. 234 ; Vehicle batteries .

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1.2 Types of battery

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These batteries are recognised by the removable cell plugs. cted agen
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Lead-acid battery, electrolyte level must be checked regularly and

topped-up with distilled water as required.
These batteries are often equipped with a magic eye. The magic
eye provides information concerning the level of the electrolyte
and the charge state of the battery.

1.2.2 Maintenance-free battery

Maintenance-free battery with liquid electrolyte (wet battery).
These batteries have a cover over the cells instead of cell plugs.
The cover seals the battery after initial filling during production.

Caution

Never under any circumstances remove the cover for the bat‐
tery cells. The battery housing will be damaged and the battery
is therefore unusable.

Lead-acid battery, where electrolyte need not be topped-up with

distilled water under normal conditions. This term is normally used
for batteries with a predetermined amount of electrolyte.

1. Battery 1
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

These batteries are often equipped with a magic eye. The magic
eye provides information concerning the level of the electrolyte
and the charge state of the battery.

1.2.3 Absorbent glass mat (AGM) battery

Maintenance-free battery with a contained electrolyte.
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croscopic glass mat (AGM). The battery is issealed
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AGM is the abbreviation for Absorbent
s Glass Mat.

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♦ The procedure for checking and testing gel and absorbent

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glass mat batteries is identical.
ole,

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♦ Always replace an absorbent glass mat battery with another

t to the co
absorbent glass mat battery.

1.2.4 Gel battery

rrectne
Maintenance-free battery with a contained electrolyte.

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Lead-acid battery where the electrolyte is contained within a gel.
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The battery is sealed and fitted with valves.

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♦ The procedure for checking and testing gel and absorbent

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1.3 Warning notices and safety regulations
Prote AG.

1.3.1 Dangers when handling vehicle batter‐

ies
Recognition and avoidance of dangers
Batteries can be dangerous. These dangers can be avoided when
the warnings on the battery and in the owners/instruction manual
and in ELSA are observed.

2 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

WARNING

♦ Untrained personnel e.g. apprentices, trainees etc. may

only work on batteries when supervised by a vehicle me‐
chanic/foreman or vehicle electrician/foreman.
♦ Acid is highly corrosive. There is a considerable danger of
acid burns if personnel do not handle batteries correctly.
Therefore suitable measures must be taken to ensure that
equipment/solutions etc. are available to neutralize acid
burns. A suitable solution is: e.g. a soap solution.
♦ If electrolyte leaks from a battery it may cause skin burns
and acid corrosion, rusting on the vehicle. This may dam‐
age safety relevant components on the vehicle.
♦ The gas which forms when charging and the gas which
may escape through vent valves is explosive. In extreme
cases a battery may explode if the battery is not handled
correctly.
♦ Grinding, welding and cutting operations are prohibited as
such operations produce sparks. Smoking is also forbid‐ AG. Volkswagen AG d
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den owing to the danger from naked flames. Sparks by gen‐
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erated by electrostatic charging must also berisavoided.
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Always touch the vehicle body before touching
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♦ Only work on batteries in well ventilated and suitable

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Safety markings on battery

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1. - Fires, sparks, naked lights and smoking are prohibited. Avoid

t to the co
sparks as well as electrostatic discharge when working with ca‐
bles and electrical units. Avoid short circuits. Therefore never lay
a tool on a battery.

rrectness of i
2. - Wear eye protection before commencing work on battery.
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3. - Keep children away from acid and batteries.

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4. - Disposal: old batteries are classed as hazardous waste. They

may only be disposed of through a suitable collection centre and
m

only in accordance with respective legislation. at

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5. - Never dispose of old batteries in household waste system!

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6. - There is a danger of an explosion when working with batteries.

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A highly explosive gas is produced when batteries are charged.

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8. - Battery acid is very caustic, therefore wear eye protection and
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AG.

leak out of the gas vents of some batteries.

1. Battery 3
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1.4 Battery terminal connection

Caution

To prevent damage to the battery terminal clamps and battery

terminals, the following should be observed:
♦ The battery terminal clamps should only be fitted by hand
and without using force.
♦ Battery terminals should not be coated with grease.
♦ The battery terminal clamps should be fitted so that the
battery terminal is either flush with the clamp or protruding
from it.
♦ Once the battery terminal clamps have been tightened to
the specified torque, the threaded connections should not
be tightened any further.
♦ When batteries are reconnected, the procedure described agen
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om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

2 Checking battery

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

Caution

To prevent damage to the battery and vehicle,

agen
the
AG. Volksfollowing
wagen AG
d
should be observed concerning types
Vo lkof
swbattery ⇒ page 1 . oes not g
by ua
ed ran
oris tee
th or
au
2.1 Procedure swhen checking a battery
s ac

ce
e
nl

pt
du

Carry out procedure in sequence as follows:

an
itte

y li
erm

1. Visual check ⇒ page 5 .

ab
ility
ot p

2. Checking battery with a magic eye ⇒ page 6 or checking

wit
, is n

a low maintenance battery ⇒ page 7 .

h re
hole

spec
3. Check no load voltage of battery ⇒ page 10 .
es, in part or in w

t to the co
4. Perform a battery load test using battery tester with printer
-VAS 5097 A- ⇒ page 12 .

rrectness of i
2.2 Visual check
l purpos

WARNING

nform
ercia

Danger of injury! Observe warning notices and safety regula‐

m

at
tions ⇒ page 2 !
om

ion
c

in t
or

his
ate

do
riv

It is essential first to check the external condition, the terminals of

p

cum
or

the battery and that the battery is seated securely visually before
f

en
g

performing more extensive tests.

n

t.
yi Co
Cop py
ht. rig
rig ht
Caution
py by
co Vo
by lksw
cted agen
Prote AG.
♦ The battery will be damaged if the battery is not secured
correctly.
♦ Vibrations shorten the life of the battery, there is a danger
of an explosion, the cell plates may be damaged and the
securing plate may damage the battery housing.
♦ Check battery is securely seated, if necessary tighten se‐
curing bolt to specified torque setting ⇒ page 36 .

Performing this test establishes:

♦ Check whether the battery housing is damaged. Electrolyte
can leak out if the housing is damaged. If battery acid leaks
out, serious damage to the vehicle could be caused. Treat
areas of the vehicle affected by leaked battery acid immedi‐
ately with acid neutraliser or a soap solution.
♦ Check whether the battery terminals (battery wire connec‐
tions) are damaged. The necessary contact at the terminal
clamps cannot be guaranteed if the terminals are damaged.
When connecting clamps to the terminals, tighten the clamps
to the torque specified in this workshop manual. If the clamps

2. Checking battery 5
 n AG. Volkswagen AG do
wage es n
Transporter 1991 ➤ , Transporter y1996 Volks ➤ ot g
b ua
Electrical system - Edition 10.2004
ir se
d ran
tee
tho
u or
a ac
are not correctly seated and tightened,
ss the wiring could burn,
which could result in electrical system malfunctions. Which will

ce
e
nl

pt
du
cause malfunctions in the electrical system. Therefore it can

an
itte

y li
no longer be guaranteed that the vehicle will function correctly.

erm

ab
ility
ot p
2.3 Checking battery with magic eye

wit
, is n

h re
hole

spec
WARNING
es, in part or in w

t to the co
Danger of injury! Observe warning notices and safety regula‐
tions ⇒ page 2 !

rrectness of i
l purpos

The magic eye provides information concerning the level of the

electrolyte and the charge state of the battery.

nf
ercia

Batteries with a magic eye are produced in two versions:

orm
m

atio
♦ Low maintenance ⇒ page 1
om

n in
or c

♦ Maintenance-free ⇒ page 1

thi
te

sd
iva

o
r
rp

cu
o

m
f

Note

en
ng

t.
yi Co
Cop py
. rig
Because the magic eye is located in only one cell, the display
t
gh ht
yri by
applies only to this cell. An exact determination of battery's con‐ cop Vo
by lksw
dition is only possible through a load test ⇒ page 12 . cted agen
Prote AG.

– Before carrying out a visual check, tap the magic eye lightly
and carefully using the handle of a screwdriver.
The air bubbles, which can influence the display, will dissipate
when doing this. The colour display of the magic eye will be more
accurate.

Note

♦ Air bubbles can form below the magic eye particularly when
the battery is being charged, including during normal vehicle
operation. These falsify the colour display of the magic eye.
♦ The magic eye can be located at various positions on the bat‐
tery.

Three different colour displays are possible:

♦ “Green”, battery is charged sufficiently.
♦ “Black”, battery partly discharged, charge state < 65 % or
completely discharged.
♦ “Colourless or yellow”, battery must be renewed.

Note

♦ Charging battery with battery charger -VAS 5095 A-

⇒ page 16 .
♦ Charging battery with battery charger -VAS 5900-
⇒ page 19 .

6 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

2.4 Checking low maintenance battery

WARNING

Danger of injury! Observe warning notices and safety regula‐ olksw

tions ⇒ page 2 ! swa
gen AG
.V agen AG
does
olk not
yV gu
edb ara
ris nte
ho electrolyte level
This battery is “low maintenance”, this meansautthe eo
ra
must be checked and occasionally topped-up ss with distilled water c
as required.

ce
e
nl

pt
du

an
itte
2.4.1 Checking battery electrolyte

y li
erm

ab
ility
ot p

Checking battery electrolyte at housing:

wit
, is n

h re
– Check electrolyte level visually at -min. and max.- markings on
hole

spec
the battery housing.
es, in part or in w

t to the co
The electrolyte level is OK when the fluid level is level with the
max. marking.
If electrolyte level is below -max.- marking:

rrectness of i
– Fill with distilled water ⇒ page 7 .
l purpos

Checking electrolyte level in cells:

nform
ercia

– Switch off ignition and all electrical consumers.

m

at
– Pull protective foil off cell plugs, if fitted.
om

ion
c

in t
or

his
ate

do
riv

Note
p

cum
for

en
ng

The stickers with the warning notices must remain on the battery.
t.
yi Co
Cop py
ht. rig
rig ht
– Remove cell plugs. py by
co Vo
by lksw
cted agen
– Check electrolyte level in battery cells. Prote AG.

The electrolyte level is OK when the fluid level is level with the
plastic marker -1-.

Note

The plastic marker equates to the max marking.

If electrolyte level is OK.:

– Check cell plugs and O-rings for damage. Damaged parts
must be renewed.
– Seal cells with cell plugs.
If electrolyte level is below plastic marker:
– Fill with distilled water ⇒ page 7 .

2.4.2 Replenishing with distilled water

Special tools and workshop equipment required

2. Checking battery 7
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

♦ Battery filler bottle -VAS 5045/-

Caution

♦ Replenishing with battery acid or anything other than dis‐

tilled water will damage the battery. Only fill with distilled
water.
♦ The battery can also be damaged by over-filling the cells
Only use the battery filler bottle -VAS 5045/- to replenish.
The design of the filler nozzle prevents any spillage or
over-filling.

– Check battery electrolyte level ⇒ page 7 .

– Switch off ignition and all electrical consumers.
– Pull protective foil off cell plugs, if fitted.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
Note ir se
d ran
tee
tho
u or
a ac
The stickers with the warning notices must remain on the battery.
ss

ce
e
nl

pt
du

an
itte

– Remove cell plugs.

y li
erm

ab
– Fill with distilled water using battery filler bottle -VAS 5045/- .

ility
ot p

The flow will stop automatically when the correct level is

wit
, is n

reached.

h re
hole

spec
– Check cell plugs and O-rings for damage. Damaged parts
es, in part or in w

must be renewed.
t to the co
– Seal cells with cell plugs.
rrectness of i

– Check battery no load voltage ⇒ page 10 .

l purpos

– Perform a battery load test ⇒ page 12 .

2.4.3 Checking specific gravity

nform
ercia

Special tools and workshop equipment required

m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

8 Rep. Gr.27 - Starter, current supply, CCS

 AG. Volkswagen AG d
ksw
agen Transporter
oes
not
1991 ➤ , Transporter 1996 ➤
ol
byV gElectrical
u system - Edition 10.2004
a
ed ran
oris tee
th
♦ Commercially available
au hydrometer
or
ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r

– Check battery electrolyte level ⇒ page 7 .

rp

cum
fo

en
ng

– Switch off ignition and all electrical consumers.

t.
yi Co
Cop py
.
– Pull protective foil off cell plugs, if fitted.
ht rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note

The stickers with the warning notices must remain on the battery.

– Remove cell plugs.

– Draw off sufficient electrolyte from one cell to ensure the float
swims.
The specific gravity (density) of the fluid determines the depth that
the float swims. The value can be read on the scale on the swim‐
mer.
Specific gravity Charge Voltage
1.28 g/cm3 100 % 12.7 V
1.21 g/cm3 60 % 12.3 V
1.18 g/cm3 40 % 12.1 V
1.10 g/cm3 0% 11.7 V

Note

Checking the specific gravity directly after replenishing with dis‐

tilled water leads to faulty readings. Check specific directly after
charging the battery.

– Check cell plugs and O-rings for damage. Damaged parts

must be renewed.
– Seal cells with cell plugs.

2. Checking battery 9
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

2.5 Checking no load voltage of battery

WARNING
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Danger of injury! Observe
ised b warning notices and safety regula‐
ara
nte
tions ⇒ page 2 ! thor eo
au ra
ss c

ce
e
nl

pt
The no load voltage test is used to determine the capacity of the
du

an
itte

battery.

y li
erm

ab
ility
ot p

wit
, is n

Note

h re
hole

spec
The battery must not be charged or discharged for at least 2 hours
es, in part or in w

t to the co
before making the measurements. Charging or discharging dur‐
ing this period falsify the test result.

rrectness of i
No load voltage Charge Condition of battery
l purpos

11.70 V 0% Discharged, no capacity. Heavily discharged

⇒ page 27 .

nform
ercia

12.20 V 50 % Over a period of time sulphate crystals build-up which can

only be reversed using a considerable amount of energy.
m

at
om

At the same time the active mass expands greatly, which

ion
c

can cause cracks, which leads to heavy corrosion at the in t

or

positive plate.
his
ate

do
riv

12.35 V 65 % ♦ On batteries with a magic eye, the display will change

p

cum
or

from green to black.

f

en
ng

t.
yi Co
op
♦ The battery should be recharged on new/vehicles which
C py
ht. rig
have been stored.
rig ht
py by
co Vo
by lksw
cted agen
12.70 V Prote
100 % Full capacity.
AG.

Special tools and workshop equipment required

♦ Hand multimeter -V.A.G 1526 B-

– Switch off ignition and all electrical consumers and pull off ig‐
nition key.
– Disconnect negative terminal on battery ⇒ page 29 .
– Wait at least 2 hours. The battery must not be charged or dis‐
charged within this period.
– Check battery no load voltage with hand multimeter -V.A.G
1526 B- .

10 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Measured value Measure to be performed

No load voltage ≥ 12.5 V No load voltage is OK., perform
a battery load test ⇒ page 10 .
No load voltage < 12.5 V Charge battery ⇒ page 15 .
If the battery has been recharged as a result of the no load test,
proceed as follows:
– Wait at least 2 hours. The battery must not be charged or dis‐
charged within this period.
– Check battery no load voltage again with hand multimeter -
V.A.G 1526 B- .
If no load voltage is < 12.5 V after recharging, renew battery
⇒ page 31 .

2.6 Battery tester with printer -VAS 5097 A-

WARNING
AG. Volkswagen AG d
agen oes
olksw not
Danger of injury! Observe warning notices and d bsafety regula‐
y V gu
ara
tions ⇒ page 2 ! horise nte
eo
ut ra
s a c
s

ce
le

It is not necessary to remove or disconnect battery when using

un

pt
an
d

battery tester with printer -VAS 5097 A- .

itte

y li
erm

ab
Battery tester with printer -VAS 5097 A- can be used to test 12 V

ility
ot p

starter batteries according to

wit
is n

h re
ole,

♦ 80 - 499 A low-temperature test current according to DIN

spec
(Deutsche Industrie Norm (German Industrial Standard))1)
urposes, in part or in wh

t to the co
♦ 95 - 574 A low-temperature test current according to IEC (In‐
ternational Engineering Consortium)

rrectne
♦ 136 - 855 A low-temperature test current according to EN/ SAE
(European Norm/Standard of Automotive Engineers)

ss
1) Batteries with a low-temperature test current of 520 A according to DIN can be

o
tested using setting for 499A according to DIN.
cial p

f inform
.
mer

atio
m

For test purposes the battery is loaded with a current which is

o

n
c

similar to the starting current required to start the vehicle. The

i
or

n thi

battery is assessed on this loading and the result is printed out.

te

sd
iva

o
pr

cum
r
fo

en
ng

Note
t.
yi Co
Cop py
t. rig
gh
♦ Observe the ⇒ Instruction Manual for battery tester with printer
ht
pyri by
Vo
o
-VAS 5097 A- or the sticker ⇒ Brief instructions for battery
c by lksw
cted agen
tester with printer -VAS 5097 A- stuck on the unit or table: Low-
Prote AG.

temperature current ⇒ page 13 .

♦ Observe battery manufacture's handling instructions!

2. Checking battery 11
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

2.6.1 Description of battery tester with printer

-VAS 5097 A-
Battery tester with printer -VAS 5097 A-
1 - Green LED, “unit operating”
2 - Red LED, “unit reverse-polarity connected”
3 - Red LED, “battery cannot be tested”, recharge battery.
4 - Start tester
5 - Low-temperature current selection switch
6 - ON/OFF and functions switch
7 - Selection switch (battery tester to pick-off point on battery/
external test point in engine compartment)
8 - Button to advance paper
9 - Printer

2.6.2 Performing battery load test using bat‐

tery tester with printer -VAS 5097 A-

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

Special tools and workshop equipment required

♦ Battery tester with printerge-VAS
n AG. V5097
olkswaA-
gen AG
d wa oes
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

Performing battery load test:

rrectness of i

– Switch off ignition and all electrical consumers.

l purpos

– Check battery no load voltage ⇒ page 10 .

– Set low-temperature test current for battery in Ampere (A) ac‐
nf
ercia

cording to Standard.
orm
m

atio

If the battery values are shown in IEC or EN/SAE instead of DIN

om

then convert figures using table

n in
or c

⇒ “2.6.3 Table: low-temperature test current”, page 13 or using

thi
te

sd
a

table on unit.
iv

o
r
rp

cu
o

– Select low-temperature test current via low-temperature test

f

en
ng

t.
current selection switch ⇒ page 12 .
yi Co
Cop py
ht. rig
– Select measuring range 80 - 379 A or 380 - 499 A with ON/ rig ht
py by
OFF and functions switch ⇒ page 12 . co Vo
by lksw
cted agen
Prote AG.
– Connect red terminal “+” of unit to positive terminal.

12 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Connect black terminal “-” of unit to negative terminal.

Note

Ensure test clamps have a good contact! AG. Volkswagen AG d

agen oes
olksw not
yV gu
– Select point of connection ofistest
ed terminals with selection
b ara
nte
switch ⇒ page 12 . hor eo
aut ra
s c
1- Connected directly to battery.
s

ce
e
nl

pt
du

2- Connected to external test points in engine compartment.

an
itte

y li
erm

ab
– Check that the figures given on the battery are correct for the

ility
ot p

settings on the battery tester.

wit
, is n

h re
– Press start test button ⇒ page 12 .
hole

spec
The green LED lights up ⇒ page 12 . The test program runs
es, in part or in w

through automatically. The test result is printed out by the printer

t to the co
⇒ page 14 .
– Switch off unit ⇒ page 12 .

rrectness of i
– Remove test terminals.
l purpos

nform
Note
mercia

at
♦ The test is completed after about 20 seconds.
om

ion
c

in t
r

♦ The result of the test is printed out by the printer.

o

his
ate

do
riv

♦ Perform test once only. Repeating the test falsifies the results.
p

cum
for

en
ng

t.
yi Co
op py
2.6.3 Table: low-temperature test current
. C rig
ht ht
rig by
copy Vo
by lksw
cted Low-temperature test current in A
agen
Prote AG.
EN/ SAE IEC ⇒ DIN
136 – 17 95 – 124 ⇒ 80 – 104
178 – 219 125 – 154 ⇒ 105 – 129
220 – 261 155 – 184 ⇒ 130 – 154
262 – 303 185 – 214 ⇒ 155 – 179
304 – 345 215 – 244 ⇒ 180 – 204
346 – 387 245 – 274 ⇒ 204 – 229
388 – 429 275 – 304 ⇒ 230 – 254
430 – 471 305 – 334 ⇒ 255 – 279
472 – 513 335 – 364 ⇒ 280 – 304
514 – 555 365 – 394 ⇒ 305 –329
556 – 597 395 – 424 ⇒ 330 – 354
598 – 639 425 – 454 ⇒ 355 – 379
640 – 657 455 – 464 ⇒ 380 – 389
658 – 675 465 – 474 ⇒ 390 – 399
676 – 693 475 – 484 ⇒ 400 – 409
694 – 711 485 – 494 ⇒ 410 – 419
712 – 729 495 – 504 ⇒ 420 – 429
730 – 747 505 – 514 ⇒ 430 – 439
748 – 765 515 – 524 ⇒ 440 – 449
766 – 783 525 – 534 ⇒ 450 – 459
784 – 801 535 – 544 ⇒ 460 – 469

2. Checking battery 13
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Low-temperature test current in A

EN/ SAE IEC ⇒ DIN
802 – 819 545 – 554 ⇒AG. Volkswagen A 470 – 479
agen G do
820 – 837 555 – 564 olksw ⇒ es n 480 – 489
ot gu
yV
838 – 855 565 – 574 db ⇒
a
490ra–nt499 2)
rise ee
tho
o
au to DIN can be tested using setting for 499A according to rDIN.
2) Batteries with a low-temperature test current of 520 A according ac
ss

ce
le
un

pt
an
d
itte

y li
2.7 Evaluating test result
erm

ab
ility
ot p

wit
Because of the high load on the battery during this test (a high
is n

h re
current flows) the battery voltage drops.
ole,

spec
urposes, in part or in wh

♦ If the battery is OK, the voltage value drops only to the mini‐

t to the co
mum voltage.
♦ If the battery is defective or has a low charge, the battery volt‐
age quickly drops below the minimum voltage.

rrectne
♦ After the test is completed, this low voltage value remains over
a longer period, and the voltage increases very slowly again.

ss o
cial p

f
♦ Perform test once only. Repeating the test falsifies the results.

inform
mer

2.7.1 Comments concerning test print out

atio
om

n
c

i
1- Measuring range selected on tester.
or

n thi
te

sd
a

2- Diagram -arrow- indicates battery condition.

iv

o
pr

cum
r
fo

3- Test result.

en
ng

t.
yi Co
op
4- Battery voltage during load test.
C py
ht. rig
rig ht
py by
5- Vehicle data and date. Must be completed by test person‐ co Vo
by lksw
nel.
cted agen
Prote AG.

Note

♦ The test printout is required for warranty claims.

♦ Perform test once only. Repeating the test falsifies the results.

2.7.2 Assessing test results

Printout from battery tester Measure to be performed
Starting output very good Battery OK
Starting output good Battery OK
Starting output sufficient Charge battery ⇒ page 15
Starting output poor and repeat battery load test 3).
Starting output very poor
Cannot be tested
3) If after battery has been recharged “Starting output sufficient”, “Starting output
poor”, “Starting output very poor” or “Cannot be tested” is shown, the battery
should be renewed.

14 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

3 Charging battery

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

Caution

To prevent damage to the battery and vehicle, the following

should be observedeconcerning
n AG. Volkswagtypes
en AG of battery ⇒ page 1 .
wag does
olks not
byV gu
ara
ed nte
ris
3.1 au
tho Battery charger -VAS 5095 A- eo
ra
ss c
This chapter describes the basic functions of the battery charger

ce
e
nl

pt
-VAS 5095 A- . For additional information refer to ⇒ Operating
du

an
itte

instructions for battery charger -VAS 5095 A- .

y li
erm

ab
ility
ot p

wit
, is n

Note
h re
hole

spec
♦ Observe ⇒ Operating instructions for battery charger -VAS
es, in part or in w

5095 A- .
t to the co

♦ Observe battery manufacturer's handling instructions!

rrectness of i

3.1.1 Description of battery charger -VAS

l purpos

5095 A-
nf
ercia

Battery charger -VAS 5095- is suitable for charging

orm
m

atio

♦ Wet batteries (genuine VW batteries from 2004 with transpar‐

om

ent battery housing and black cover).

n in
or c

thi
e

♦ Absorbent glass mat batteries (genuine VW batteries from

t

sd
iva

2004 with black housing).

r
rp

cu
o

m
f

en
ng

The battery charger charges without peaks in amperage or volt‐

t.
yi Co
op
age. This will not adversely effect the Ø electronics. The battery
C py
ht. rig
can remain in the vehicle while it is being charged and need not
rig ht
py by
be disconnected. co Vo
by lksw
cted agen
Prote AG.
Battery charger -VAS 5095 A-
1 - ON / OFF switch (0 = charger OFF)
2 - Charging current indicator (I > 12 A)
3 - Charging current indicator, battery partially charged > 90 %
4 - Maintaining charge, lights up green when battery is fully charg‐
ed
5 - Malfunction indicator
6 - Support mode indicator
7 - Support mode/normal mode changer-over switch
8 - Charger cable posts, red terminal “+”, black terminal “-”
9 - Battery type change-over switch (on base of charger unit)

3. Charging battery 15
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

3.1.2 Charging battery with battery charger -

VAS 5095 A-

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

Special tools and workshop equipment required

♦ Battery charger -VAS 5095 A-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
Caution s

ce
le
un

pt
an
d

Always set battery type 2.4 V/C (Volt/Cells) when charging!

itte

y li
erm

This applies for all batteries.

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

Note

t to the co
♦ The battery must have a temperature of at least 10 °C.

rrectne
♦ If the battery has cell sealing plugs, do not open them while
the battery is being charged. ss o

– Switch off ignition and all electrical consumers.

cial p

f inform

– Check setting for battery type on type of battery switch

mer

⇒ page 15 . Must be set to 2.4 V/C (Volt/Cells).

atio
om

n
c

– Connect red terminal clamp “+” of charger unit to positive ter‐

i
or

n thi
e

minal on battery.
t

sd
iva

o
pr

– Connect black terminal clamp “-” of charger unit to negative

um
r
fo

terminal on battery.
en
ng

t.
yi Co
op py
– Switch on battery charger ⇒ page 15 . t. C rig
gh ht
pyri by
The charging current indicators ⇒ page 15 -2- and -3- light up
o Vo
by c lksw
cted agen
yellow. When only the light emitting diode (LED) -3- lights up yel‐ Prote AG.
low, battery is partially discharged (approx. 90 %).
If the LED lights up green ⇒ page 15 -4- the charger has switched
to "maintaining charge". The battery is fully charged.
– Switch off charging unit ⇒ page 15 .
– Remove charger unit terminals from battery terminals.

16 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

3.1.3 Charging totally discharged battery with

battery charger -VAS 5095 A-

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

The charger unit automatically recognises totally discharged bat‐

teries and initiates a gentle charging procedure with a low charg‐
ing current. The charging current is automatically adapted to suit
the charge condition of the battery.

Note

♦ Observe notes in chapter ⇒ page 27 .

♦ The battery voltage must be at least 0.6 V.

– Charge battery ⇒ page 16 .

3.1.4 Charging battery in support mode with

battery charger -VAS 5095 A-

WARNING

Danger of injury! Observe warning notices

agen
Aand
G. Vosafety
lkswageregula‐
n AG d
tions ⇒ page 2 ! Volksw
oes
not
g
y ua
db ran
rise tee
ho
ut or
When in support mode the
ss abattery charger -VAS 5095 A- replaces ac
a defective vehicle battery whilst it is being exchanged. The on‐
ce
e
nl

pt

board supply remains intact. The vehicles electrical equipment

du

an
itte

(e.g. electric windows) can be used.

y li
erm

ab
ility

Special tools and workshop equipment required

ot p

wit
, is n

♦ Battery charger -VAS 5095 A-

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r

Caution
rp

cu
o

m
f

en
ng

t.
yi Co
♦ Always set battery type 2.4 V/C (Volt/Cells) when in sup‐ Cop py
port mode! This applies for all batteries.
t. rig
gh ht
pyri by
Vo
co
♦ The battery charger -VAS 5095 A- terminal clamps must
by lksw
cted agen
Prote
remain in contact with the battery terminal clamps whilst
AG.

the battery is being exchanged.

3. Charging battery 17
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Switch off ignition and all electrical consumers.

– Set support mode/normal mode change-over switch to “sup‐
port mode” ⇒ page 15 .
– Connect red terminal clamp “+” of charger unit to positive ter‐
minal of vehicle.
– Connect black terminal clamp “-” of charger unit to negative
terminal of vehicle.
– Check setting for battery type on type of battery switch
⇒ page 15 . Must be set to 2.4 V/C (Volt/Cells).
– Switch on battery charger ⇒ page 15 .
The yellow LEDs ⇒ page 15 -6- and -3- light up.

Note

♦ A minimum load of 0.6 A (e.g. parking light) must be switched

on, otherwise support mode is not possible.
♦ During the support mode the current draw is limited to 5 A.

– Switch on vehicle parking light.

– Exchange battery ⇒ page 31 .
– Switch off charging unit ⇒ page 15 .
– Remove charger unit terminals from battery terminals.
– Set support mode/normal mode change-over switch to “nor‐
mal mode” again ⇒ page 15 .
G. Volkswagen AG d
3.1.5 Charging battery in buffer/ maintenance
olksw
agen
A
oes
not
mode with battery chargered -VAS 5095 A-
V gu
by ara
ris nte
tho eo
s au ra
c
WARNING s
ce
e
nl

pt
du

an
itte

Danger of injury! Observe warning notices and safety regula‐

y li
erm

ab

tions ⇒ page 2 !
ility
ot p

wit
, is n

h re

In the buffer mode the battery charger -VAS 5095 A- is charged

hole

spec

correctly and is maintained in a fully charged condition.

es, in part or in w

t to the co

– Proceed as for charging battery ⇒ page 16 .

rrectness of i

Note
l purpos

♦ When a battery is being charged in the buffer mode and a

consumer draws current from the battery, the battery charger
nf
ercia

-VAS 5095 A- automatically compensates the charge.

orm
m

atio

♦ The buffer mode can be continued for an unlimited period.

om

n in
or c

♦ The battery is always ready for use.

thi
te

sd
iva

♦ Observe battery manufacture's maintenance instructions!

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

18 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

3.2 Battery charger -VAS 5900-

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

AG. Volkswagen A
This chapter describes
olks
wage the basic functions
n G do
esof
nothe battery charger
-VAS 5900-d b. yFor additional information refer to
V t gu⇒ Operating in‐
ara
structions
or for battery charger -VAS 5900- .
ise nte
e
th or
au ac
ss

ce
le

Note
un

pt
an
d
itte

y li
rm

♦ Observe ⇒ Operating instructions for battery charger -VAS

ab
pe

ility
5900- .
ot

wit
, is n

♦ Observe battery manufacturer's handling instructions!

h re
hole

spec
es, in part or in w

3.2.1 Description of battery charger -VAS

t to the co
5900-

rrectness of i
Battery charger -VAS 5900- is suitable for charging
l purpos

♦ Wet batteries (genuine VW batteries from 2004 with transpar‐

ent battery housing and black cover).
nform
ercia

♦ Absorbent glass mat batteries (genuine VW batteries from

2004 with black housing).
m

a
com

tio

Battery charger -VAS 5900-

n in
r
te o

thi

1 - Display
s
iva

do
r
rp

2 - Adjustment button “Up” ↑

um
fo

en
ng

t.
yi
3 - Adjustment button “Down” ↑
Co
Cop py
t. rig
gh ht
4 - START / STOP
yri
p by
co Vo
by lksw
cted agen
5 - INFO Prote AG.

3.2.2 Charging battery with battery charger -

VAS 5900-

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

Special tools and workshop equipment required

3. Charging battery 19
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

♦ Battery charger -VAS 5900-

Note

♦ The battery must have a temperature of at least 10 °C.

♦ If the battery has cell sealing plugs, do not open them while
the battery is being charged.

– Switch off ignition and all electrical consumers. AG. Volkswagen AG d

agen oes
lksw not
– Connect charger unit plug to power supply. The last selected d by
Vo gu
ara
operating mode will appear on display ⇒ page 19 . orise nte
h eo
ut ra
– Set battery to respective operating mode with INFOss.a c

ce
e
nl

In the display the symbol -1- for “standard charge for wet batter‐

pt
du

an
ies” or symbol -2- for “standard charge for gel/absorbent glass
itte

y li
erm

mat batteries” will appear.

ab
ility
ot p

– Set battery capacity (Ah) of battery for charging using respec‐

wit
, is n

tive button “Up” ↑ or “Down” ↓ .

h re
hole

spec
– Connect red terminal clamp “+” to positive terminal on battery.
es, in part or in w

t to the co
– Connect black terminal clamp “-” to negative terminal on bat‐
tery.

rrectness of i
The charger unit recognises the voltage required for the connec‐
ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.
l purpos

At a charge condition of approx. 80 - 85 % the charger unit

nform
ercia

switches to the “final charge” mode. The fourth bar appears in

display -1-. The battery is ready for use.
m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

20 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

At a charge condition of 100 % all bars appear in display.

Note

♦ In the operating mode “standard charge” the parallel use of

consumers while charging is possible. The charging period will
. Volkswagen AG
be longer. lkswa gen AG does
n o ot g
yV
♦ The battery charger
ise will switch to maintenance mode afteran
db ar u
about 1-7 hours,
ut
hodepending on type of battery. To achieve a e o
r te
100 % chargess the battery should remain connected for this
a ra
c
period.

ce
le
un

pt
an
d
itte

y li
Possible faults and fault rectification:
rm

ab
pe

ility
1- Displayed battery voltage is not as per nominal voltage:
ot

wit
, is n

h re
– Press respective button “Up” ↑ or “Down” ↓ until charging
hole

spec
sequence starts.
es, in part or in w

t to the co
2- Displayed battery voltage is not as per nominal voltage –
charging sequence already started:
– Press START / STOP twice.

rrectness of i
– Press respective button “Up” ↑ or “Down” ↓ until charging
l purpos

sequence starts again.

nform
3- Battery charger does not detect a battery, when battery volt‐
ercia

age is less than 2 V:

m

a
com

tio
Display remains unchanged.
n in
r
te o

thi

The operating mode and ampere hours (Ah) as set are displayed.
s
iva

do
r
rp

Ending battery charging sequence:

um
fo

en
ng

t.
– Press START / STOP .
yi Co
Cop py
ht. rig
– Disconnect black terminal clamp “-” of charger unit from neg‐ rig ht
py by
ative terminal on battery.
co Vo
by lksw
cted agen
Prote AG.
– Disconnect red terminal clamp “+” of charger unit from positive
terminal on battery.
– Pull charger unit plug out of power supply socket.

3.2.3 Charging battery in service mode with

battery charger -VAS 5900-

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

Caution

The operating mode “service charge” is not permitted on VW

vehicles as the voltage peaks will damage the onboard elec‐
tronics.
If there is a requirement to use “service charge” the battery
must be disconnected from the onboard supply.

3. Charging battery 21
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Caution

When charging always set the battery charger to the correct

type of battery ⇒ Operating instructions for battery charger -
VAS 5900- !
“Service charge” must only be used for:
♦ Wet batteries, where distilled water can be replenished.
♦ Gel/absorbent glass mat batteries.
Do not use operating mode “service charge” with maintenance-
free wet batteries ⇒ page 1 .

The operating mode “service charge (SERV)” is only used on

suspect defective batteries (e.g. sulphation). The battery will be
charged to maximum specific gravity and the plates will be reac‐
tivated (dissipation of sulphur layer).
Special tools and workshop equipment required
♦ Battery charger -VAS 5900-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
Note

rrectness of i
♦ The battery must have a temperature of at least 10 °C.
l purpos

♦ If the battery has cell sealing plugs, do not open them while
the battery is being charged.
nform
ercia

– Switch off ignition and all electrical consumers.

m

at
om

ion

– Connect charger unit plug to power supply. The last selected

c

in t
or

operating mode will appear on display ⇒ page 19 .

his
ate

do
riv

– Set battery to respective operating mode with INFO .

p

cum
for

en
ng

t.
In the display the symbol -1- for “service charge for wet batteries”
yi Co
op
or symbol -2- for “service charge for gel/absorbent glass mat bat‐
C py
t. rig
gh
teries” will appear.
ht
pyri by
Vo
co lksw
by
– Set battery capacity (Ah) of battery for charging using respec‐
cted agen
Prote AG.
tive button “Up” ↑ or “Down” ↓ .
– Connect red terminal clamp “+” to positive terminal on battery.
– Connect black terminal clamp “-” to negative terminal on bat‐
tery.
The charger unit recognises the voltage required for the connec‐
ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.

22 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

At a charge condition of approx. 80 - 85 % the charger unit

switches to the “final charge” mode. The fourth bar appears in
display -1-. The battery is ready for use.

Note

The success of the “service charge” depends on the severity of

the sulphation of the battery

Possible faults and fault rectification:

1- Displayed battery voltage is not as per nominal voltage:
– Press respective button “Up” ↑ or “Down” ↓ until charging
sequence starts. AG. Volkswagen AG d
agen oes
lksw n o ot g
yV
2- Displayed battery voltage is not asiseper
d b nominal voltage – ua
ran
charging sequence already started:
thor tee
or
au ac
– Press START / STOP twice. ss

ce
e
nl

pt
du

– Press respective button “Up” ↑ or “Down” ↓ until charging

an
itte

y li
sequence starts.
erm

ab
ility
ot p

3- Battery charger does not detect a battery, when battery volt‐

wit
, is n

age is less than 2 V:

h re
hole

spec
Display remains unchanged.
es, in part or in w

t to the co
The operating mode and ampere hours (Ah) as set is displayed.
Ending battery charging sequence:

rrectness of i
– Press START / STOP .
l purpos

– Disconnect black terminal clamp “-” of charger unit from neg‐

ative terminal on battery.

nf
ercia

o
– Disconnect red terminal clamp “+” of charger unit from positive

rm
terminal on battery.
m

atio
om

n in
c

– Pull charger unit plug out of power supply socket.

or

thi
te

sd
iva

3.2.4 Charging totally discharged batteries

r
rp

cu
o

m
f

en
ng

with battery charger -VAS 5900-

t.
yi Co
Cop py
ht. rig
rig ht
py by
WARNING co Vo
by lksw
cted agen
Prote AG.
Danger of injury! Observe warning notices and safety regula‐
tions ⇒ page 2 !

3. Charging battery 23
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Caution

♦ The terminal polarity protection in operating mode “charg‐

ing totally discharged batteries/support mode” is not ac‐
tive. Connect battery charger terminal clamps correctly to
battery terminals.
♦ When charging always set the battery charger to the cor‐
rect type of battery ⇒ Operating instructions for battery
charger -VAS 5900- !
♦ Totally discharged battery is not recognised by battery
charger ⇒ page 27 .
♦ Do not press START / STOP button when charger unit
cables are connected incorrectly. The charger unit may be
damaged.

Batteries with a voltage of less than 2 Volt will not be recognised

automatically by battery charger -VAS 5900- .
Special tools and workshop equipment
AG. Volksrequired
wagen A
gen G do
swa es n
♦ Battery charger -VAS
by
Vol 5900-
k ot g
ua
ed ran
oris tee
th or
au ac
ss
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

Note
l purpos

♦ The battery must have a temperature of at least 10 °C.

nform
ercia

♦ If the battery has cell sealing plugs, do not open them while
m

the battery is being charged.

com

tion in
r
te o

thi

– Switch off ignition and all electrical consumers.

s
iva

do
r
rp

– Connect charger unit plug to power supply. The last selected

um
fo

en

operating mode will appear on display ⇒ page 19 .

ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

24 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Set battery to respective operating mode with INFO .

In the display the symbol -1- for “service charge for wet batteries”
or symbol -2- for “service charge for gel/absorbent glass mat bat‐
teries” will appear.
– Set battery capacity (Ah) of battery for charging using respec‐
tive button “Up” ↑ or “Down” ↓ .
– Connect red terminal clamp “+” to positive terminal on battery.
– Connect black terminal clamp “-” to negative terminal on bat‐
tery.
– Press START / STOP for approx. 5 seconds. The menu
“charging totally discharged batteries/support mode” will be swagen AG. Volkswagen AG does
activated. by
Vol
k not
gu
d ara
se nte
– Press respective button “Up” ↑ or “Down” ↓ to set tho the re‐
ri e or
spective battery voltage (6 V, 12 V or 24 V). ss au ac

ce
le
un

pt
an
d
itte

Note

y li
rm

ab
pe

ility
If a button is not pressed within 5 seconds the charger will return
ot

wit
, is n

to the main menu (select operating mode).

h re
hole

spec
– Confirm the selected battery voltage with START / STOP .
es, in part or in w

t to the co
Then follows the enquiry for "is charger cable terminal polarity
correct".

rrectness of i
– Check polarity of charger unit cables.
l purpos

– Confirm polarity of charger unit cables with START / STOP .

Charger will start charging sequence for totally discharged bat‐

nform
ercia

tery.
m

a
com

ti
Ending battery charging sequence:

on in
r
te o

thi
– Press START / STOP .

s
iva

do
r
rp

– Disconnect black terminal clamp “-” of charger unit from neg‐

cum
fo

ative terminal on battery.

en
ng

t.
yi Co
op
– Disconnect red terminal clamp “+” of charger unit from positive
C py
t. rig
gh
terminal on battery.
ht
pyri by
Vo
co lksw
by
cted
– Pull charger unit plug out of power supply socket.
agen
Prote AG.

3.2.5 Charging battery in support mode with

battery charger -VAS 5900-

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

3. Charging battery 25
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Caution

♦ The terminal polarity protection in operating mode “charg‐

ing totally discharged batteries/support mode” is not ac‐
tive. Connect battery charger terminal clamps correctly to
battery terminals.
♦ When charging in support mode always set the battery
charger to the correct type of battery ⇒ Operating instruc‐
tions for battery charger -VAS 5900- !
♦ Do not press START / STOP button when charger unit
cables are connected incorrectly. The charger unit may be
damaged.

When in support mode the battery charger -VAS 5900- replaces

a defective vehicle battery whilst it is being exchanged. The on‐
board supply remains intact. The vehicles electrical equipment
(e.g. electric windows) can be used.
Special tools and workshop equipment required
♦ Battery charger -VAS 5900-
gen AG
. Volkswagen AG
d wa oes
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

Note
l purpos

The battery must have a temperature of at least 10 °C.

nf
ercia

– Switch off ignition and all electrical consumers.

orm
m

atio

– Connect charger unit plug to power supply. The last selected

om

n in

operating mode will appear on display ⇒ page 19 .

or c

thi
te

– Press START / STOP for approx. 5 seconds. The menu

sd
iva

o
r

“charging totally discharged batteries/support mode” will be

rp

cu
o

activated.
f

en
ng

t.
yi Co
op
– Press respective button “Up” ↑ or “Down” ↓ to set the re‐
C py
t. rig
gh
spective onboard supply voltage (6 V, 12 V or 24 V).
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note

If a button is not pressed within 5 seconds the charger will return

to the main menu (select operating mode).

– Confirm the selected battery voltage with START / STOP .

– Connect red terminal clamp “+” of charger unit to positive ter‐
minal of vehicle.
– Connect black terminal clamp “-” of charger unit to negative
terminal of vehicle.

26 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Then follows the enquiry for "is charger cable terminal polarity
correct".
– Check polarity of charger unit cables.
– Confirm polarity of charger unit cables with START / STOP .
The battery charger starts with support mode.
– Exchange battery ⇒ page 31 .
– Press START / STOP . The support mode is terminated.
– Disconnect black terminal clamp “-” of charger unit from neg‐
ative terminal of vehicle.
– Disconnect red terminal clamp “+” of charger unit from positive
AG. Volkswagen AG d
terminal of vehicle. lksw
agen oes
n o ot g
yV ua
– Pull charger unit plug out of power supply
isesocket.
db ran
r tee
ho
ut or
3.2.6 Charging battery in maintenance mode ss
a ac

with battery charger -VAS 5900-

ce
e
nl

pt
du

an
itte

y li
erm

ab
WARNING

ility
ot p

wit
, is n

Danger of injury! Observe warning notices and safety regula‐

h re
hole

tions ⇒ page 2 !

spec
es, in part or in w

t to the co
When the battery is fully charged the battery charger -VAS 5900-
switches to maintenance mode.

rrectness of i
– Proceed as for charging battery ⇒ page 19 .
l purpos

At a charge condition of 100 % all bars appear in display.

nf
ercia

orm
Note
m

atio
om

n in
c

♦ When a battery is being charged in the maintenance mode and

or

thi
e

a consumer draws current from the battery, the battery charger

t

sd
iva

-VAS 5900- automatically compensates the charge.

r
rp

cu
o

m
f

en
ng

♦ The maintenance mode can be continued for an unlimited pe‐

t.
yi Co
op
riod. C py
t. rig
gh ht
yri
♦ The battery is always ready for use.
p by
co Vo
by lksw
cted agen
♦ Observe battery manufacture's maintenance instructions!
Prote AG.

3.3 Totally discharged batteries

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

A battery is designated “totally discharged” when the "no load"

voltage is less than 12.2 V.

3. Charging battery 27
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Caution

♦ Totally discharged batteries freeze prematurely.

♦ Frozen batteries should no longer be used.

Note

♦ Batteries that have not been used for a long time e.g. vehicles
that have been stored, self-discharge.
♦ In totally discharged batteries, the electrolyte is comprised al‐
most entirely of water because the acid content is so low.
♦ Totally discharged batteries sulphate, that means, the entire
plate surfaces of the battery harden.
♦ If a battery is recharged shortly after it has totally lost its
charge, the sulphation will dissipate.
♦ If these batteries are not recharged, the plates continue to
harden and the ability to recharge is reduced. The result of
which is a reduction in the battery output.

– Check battery no load voltage ⇒ page 10 .

– Charge battery.
Charging battery with battery charger -VAS 5095 A- ⇒ page 16 .
Charging battery with battery charger -VAS 5900- ⇒ page 19 .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

28 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

4 Disconnecting and reconnecting bat‐

teries

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

4.1 Disconnecting battery

Note

♦ By disconnecting the battery earth wire (open circuit), safety

is ensured when carrying out work on the electrical system.
♦ The battery positive wire need only be disconnected for re‐
moval of the battery.
♦ The battery earth wire should not be detached from the vehicle
body.

– Switch off ignition and all electrical consumers. AG. Volkswagen AG d

agen oes
olksw not
– Loosen securing nut -4- and remove negative terminal
d by
V clamp gu
ara
-3- from battery. orise nte
eo
h
ut ra
– Loosen securing nut -2- and remove positive
ss a
terminal clamp c
-1- from battery.

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
4.2 Connecting battery
rrectness of i
l purpos

Caution
nf
ercia

Observe notes on battery pole connection ⇒ page 4 .

rm
m

atio
om

n in
or c

Special tools and workshop equipment required

thi
te

sd
iva

♦ Torque wrench -V.A.G 1331-

r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4. Disconnecting and reconnecting batteries 29

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Attach positive terminal clamp -1- to battery positive terminal.

– Tighten securing bolt of positive terminal clamp -2- to specified
torque setting ⇒ page 36 .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le

– Fit negative terminal clamp -3- onto battery negative terminal.

un

pt
an
d
itte

y li
– Tighten securing bolt of negative terminal clamp -4- to speci‐
erm

ab
fied torque setting ⇒ page 36 .

ility
ot p

wit
is n

– Carry out the procedures as detailed in the table.

h re
ole,

spec
Steps after connecting battery
urposes, in part or in wh

t to the co
Procedures Performed
Ignition with ignition key: Switch

rrectne
on ignition and then switch off
again.

s
Read fault memories for all sys‐

s o
tems:
cial p

f inform
Clock : Check settings and ad‐
mer

just if necessary.

atio
om

Electric windows: Open all win‐

n
c

i
or

n
dows fully and close them

thi
te

sd
a

again, operate switch again in

iv

o
r

position “close” and hold in this

p

cum
r
fo

position until the control unit

en
ng

t.
yi
switches.
Co
Cop py
t. rig
Functional check: Check all
gh ht
pyri by
electrical consumers.
o Vo
by c lksw
cted agen
Prote AG.
If necessary, table can be printed out.

30 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

5 Removing and installing battery

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !
AG. Volkswagen AG d
agen oes
ksw
Special tools and workshop equipment required by Vol not
gu
d ara
ise nte
♦ Torque wrench -V.A.G 1331- thor eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

5.1 Battery in engine compartment

nf
ercia

o
Note

rm
m

atio
om

n in
♦ On vehicles ▸ 04.99 the height of the battery base strip is 19
or c

mm.

thi
te

sd
iva

o
r

♦ On vehicles 05.99 ▸ the height of the battery base strip is 10.5

rp

cu
o

m
mm.
f

en
ng

t.
yi Co
op
♦ From January 2001 replacement batteries are supplied filled C py
t. rig
and charged. The variety of batteries is reduced by using a
gh ht
pyri by
floor strip adapter and ventilation plugs for the degassing. The
co Vo
by lksw
cted
installation of the ventilation plugs for the degassing and the
agen
Prote AG.
installation of the floor strip adapter are described in the bat‐
tery installation instructions.

Removing:
– Remove battery cover:
– On vehicles with long front ends, loosen the clamping bolt
-arrow- 1/2 turn and remove battery cover -1- (if fitted).
– On vehicles with short front ends, unscrew M6×15 bolts.

Caution

To disconnect and connect the battery, the procedure descri‐

bed in the workshop manual should be strictly adhered to
⇒ page 29 .

– Disconnect battery ⇒ page 29 .

5. Removing and installing battery 31

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Remove hexagon bolt -3-.

– Remove clamping bracket -2- and remove battery upwards.
Installing:

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
– Install battery so that
ut the lug of the clamping bracket -1- en‐
ho eo
ra
gages in the centre
ss a battery base strip recess -arrow-. c

ce
e
nl

– On batteries with a hose for central venting ensure that the

pt
du

an
hose is not squashed. Only then can the battery vent freely.
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

32 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Ensure that the opening on the upper side of the battery cover
is not blocked on batteries with no hose for central venting.
1 - Retaining strip for battery lower flange
2 - Clamping bracket must press on battery base strip
3 - Hexagon bolt M8×30
4 - Battery securing pedestal
– Install clamping bracket -2-.
– Tighten securing bolt -3- to specified torque setting.

Caution

To disconnect and connect the battery, the procedure descri‐

bed in the workshop manual should be strictly adhered to
⇒ page 29 .

– Reconnect battery ⇒ page 29 .

– Mount battery cover according to vehicle version.
. Volkswagen AG
gen AG does
– Tighten threaded connections to specified torque settingsVolkswa not
⇒ page 36 . ed
by gu
ara
is nte
or eo
– After installing, check that battery is seated securely.
au
th ra
ss c

ce
le
un

pt
Caution

an
d
itte

y li
rm

ab
A loosely fitted battery creates the following dangers:
pe

ility
ot

wit
, is n

♦ Shortened service life due to damage from vibration (dan‐

h re
ger of explosion).
hole

spec
es, in part or in w

♦ The cells in the battery will be damaged if the battery is

t to the co
not secured correctly.
♦ Damage to battery housing by clamping bracket (possi‐
bility of acid leaking, with high consequential costs).

rrectness of i
♦ Poor crash safety.
l purpos

nform
ercia

5.2 Second battery under driver seat

m

a
com

tion in

Removing:
r
te o

thi
s
iva

– Slide driver seat forwards to stop by operating lever -1-.

do
r
rp

cum
fo

– Swing lever -2- upwards and slide seat further forward, beyond
en
ng

t.
the stop.
yi Co
Cop py
t. rig
gh ht
yri by
Caution
cop Vo
by lksw
cted agen
Prote AG.

To disconnect and connect the battery, the procedure descri‐

bed in the workshop manual should be strictly adhered to
⇒ page 29 .

5. Removing and installing battery 33

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Disconnect battery ⇒ page 29 .

– Remove hexagon bolt -3-.
– Remove clamping bracket -2- and remove battery upwards.
Installing:

Note

♦ On vehicles ▸ 04.99 the height of the battery base strip is 19

mm. A 63 Ah / 300 A battery is installed on these vehicles.
♦ On vehicles 05.99 ▸ the height of the battery base strip is 10.5 wage
n AG. Volkswagen AG do
es n
mm. A 60 Ah / 280 A battery is installed on these vehicles. yV
olks ot g
ua
b
ed ran
♦ From January 2001 replacement batteries are supplied filled horis tee
and charged. The variety of batteries is reduced by usings au a
t or
ac
floor strip adapter and ventilation plugs for the degassing. The
s

ce
le
installation of the ventilation plugs for the degassing and the un

pt
an
d
installation of the floor strip adapter are described in the bat‐
itte

y li
tery installation instructions.
erm

ab
ility
ot p

wit
is n

h re
WARNING
ole,

spec
urposes, in part or in wh

Under the driver's seat 175 mm high batteries must not be ex‐

t to the co
changed with or replaced by 190 mm high batteries.

rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

34 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1 - Retaining strip for battery lower flange

2 - Clamping bracket must press on battery base strip
3 - M8×25 hexagon bolt
4 - Battery securing pedestal
– Install clamping bracket -2-.
– Tighten securing bolt -3- to specified torque setting.

Caution

To disconnect and connect the battery, the procedure descri‐

bed in the workshop manual should be strictly adhered to
⇒ page 29 .

– Reconnect battery ⇒ page 29 .

– Tighten threaded connections to specified torque settings
⇒ page 36 .
– After installing, check that battery is seated securely.

Caution

A loosely fitted battery creates the following dangers:

♦ Shortened service life due to damage from vibration (dan‐
ger of explosion).
♦ The cells in the battery will be damaged if the battery is
not secured correctly.
♦ Damage to battery housing by clamping bracket (possi‐
bility of acid leaking, with high consequential costs).
♦ Poor crash safety.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
by
35
copy Vo
by lksw
cted agen 5. Removing and installing battery
Prote AG.
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

6 Torque settings: battery

Threaded connections Torque settings
Battery clamp to battery terminal M6 6 Nm
Additional clamp to battery terminal clamp M6
n AG. Volkswagen AG do
6 Nm
wage es n
Securing bolt of battery holdery V(engine
olks com‐ M8x30 ot g 23 Nm
partment battery) ir se
db ua
ran
tee
Securing bolt ho M6x15 10 oNm
aut ra
of battery cover, short
ss front end (engine com‐ c

ce
partment battery)
e
nl

pt
du

an
Securing bolt of battery holder (second bat‐ M8x25 20 Nm
itte

y li
erm

tery)

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

36 Rep. Gr.27 - Starter, current supply, CCS

 AG. Volkswagen AG d
agen oes
olksw not
y V gu
rise
d b
Transporter 1991 ➤ , Transporter
ara
nte 1996 ➤
autho
Electrical system - Edition
eo
r ac
10.2004
ss

ce
le
un

pt
7 Starter

an
d
itte

y li
rm

ab
pe

ility
ot
Caution

wit
, is n

h re
hole
To disconnect and connect the battery, the procedure descri‐

spec
bed in the workshop manual should be strictly adhered to

es, in part or in w

t to the co
⇒ page 29 .

rrectness of i
l purpos

Note

When the battery is reconnected, remember to check the vehicle

nform
ercia

ancillaries (radio, clock, convenience electronics, electric window

m

regulators, etc.) in accordance with the workshop manual and/or

a
com

tio
operating instructions.

n in
r
te o

thi
s
iva

Depending on the engine and gearbox type, 12 V starters with 1.1

do
r
rp

c
kW or 2.0 kW output are fitted in the vehicles (assignment as

um
fo

specified in the parts catalogue).

en
ng

t.
yi Co
op py
7.1 Removing and installing starter
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

7.1.1 Vehicles with manual gearbox

Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

♦ Torque wrench -V.A.G 1332-

7. Starter 37
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Caution

To disconnect and connect the battery, the procedure descri‐

bed in the workshop manual should be strictly adhered to
⇒ page 29 .

– Disconnect battery ⇒ page 29 .

– Pull black plastic cap off solenoid switch if necessary.
– Release connector housing terminal 50 -arrow- and pull off.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
– Unscrew hexagon nut at solenoid switch terminal 30 -arrow-
hole

spec
and disconnect cable.
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

– Remove securing bolts -arrows-.

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

38 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Remove securing bolt -arrow-.

– Remove starter.
Installation is carried out in the reverse order. When installing,
note the following:
– Tighten threaded connections to specified torque settings
⇒ page 42 .

7.1.2 Vehicles with automatic gearbox

Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
♦ Torque wrench -V.A.G 1332-
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

Caution
m

at
om

io

To disconnect and connect the battery, the procedure descri‐

n
c

in t

bed in the workshop manual should be strictly adhered to

or

his
e

⇒ page 29 .
at

do
priv

cum
for

en
ng

t.
yi
– Disconnect battery ⇒ page 29 .
Co
Cop py
ht. rig
– Pull black plastic cap off solenoid switch if necessary. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

7. Starter 39
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Release connector housing terminal 50 -arrow- and pull off.

– Unscrew hexagon nut at solenoid switch terminal 30 -arrow-

and disconnect cable.

– Unscrew hexagon nut -arrow- if necessary and remove brack‐

et.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl

pt
du

– Remove securing bolt -arrow-. an

itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
40
AG.
Rep. Gr.27 - Starter, current supply, CCS
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Remove securing bolt -arrow-.

– Remove starter.
Installation is carried out in the reverse order. When installing,
note the following:
– Tighten threaded connections to specified torque settings
⇒ page 42 .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

7. Starter 41
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

8 Torque settings: starter

Threaded connections Torque settings
Starter securing bolt to gearbox (manual M8 20 Nm
gearbox)
Starter securing bolt to gearbox (automatic M10 60 Nm
gearbox)
Hexagon nut to starter securing bolt (auto‐ M6 10 Nm
matic gearbox)
B+ wire to starter solenoid switch (terminal M8 13 Nm
30)

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

42 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

9 Alternator with V-belt

Note

Checking alternator ⇒ Current flow diagrams, Electrical fault find‐

ing and Fitting locations.

9.1 4-cylinder petrol engine

1 - V-belt
❑ Checking and adjusting
V-belt tension
⇒ page 48
❑ V-belt drive for alterna‐
tor and coolant pump
⇒ page 46
❑ V-belt drive for alterna‐
tor and power assisted
steering vane pump
⇒ page 47
. Volkswagen AG
gen AG does
2 - Allen head bolt Vol
ksw
a
not
by gu
❑ M8×95 ris
ed
ara
nte
o eo
❑ 35 Nm au
th
ra
ss c
3 - Bush
ce
e
nl

pt
du

an

4 - Bracket
itte

y li
erm

ab

5 - Washer
ility
ot p

wit
, is n

6 - Hexagon bolt M8×35

h re
hole

❑ 30 Nm
spec
es, in part or in w

7 - Hexagon bolt M8×35

t to the co

❑ 30 Nm
8 - Stud
rrectness of i

9 - Alternator
l purpos

❑ Repairing - 65 A (Valeo
version) ⇒ page 109
nf
ercia

or

❑ Repairing - 90 A (Bosch
m
m

atio

version) ⇒ page 113

om

n in
or c

10 - Fan gear
thi
te

sd
a

❑ Note direction of rota‐

iv

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

9. Alternator with V-belt 43

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

tion, marked by arrow

11 - Belt pulley
❑ Diameter 70 mm.
❑ Removing and installing - 65 A (Valeo version) ⇒ page 111
❑ Removing and installing - 90 A (Bosch version) ⇒ page 115
12 - Hexagon nut
❑ 50 Nm
13 - Washer
14 - Hexagon bolt M8×35
❑ 35 Nm
15 - Socket head fastener
16 - Tensioning arm
❑ with tensioning device
17 - Lifting eye
18 - M8×20 hexagon bolt
❑ 20 Nm
19 - Washer AG. Volkswagen AG d
agen oes
lksw not
20 - M8×20 hexagon bolt d by
Vo gu
ara
e nte
❑ 20 Nm horis
eo
aut ra
21 - Shim ss c
ce
e
nl

pt
22 - Washer
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

44 Rep. Gr.27 - Starter, current supply, CCS

 AG. Volkswagen AG d
agen oes
olksw not
yV gu
ed b Transporter ar1991
an ➤ , Transporter 1996 ➤
ris tee
tho Electrical osystem - Edition 10.2004
au ra
c
ss
9.2 4-cylinder diesel engine

ce
e
nl

pt
du

an
itte

y li
erm

ab
1 - Hexagon nut

ility
ot p

wit
, is n
❑ 50 Nm

h re
hole

2 - Washer

spec
es, in part or in w

t to the co
3 - Belt pulley
❑ Diameter 70 mm.
❑ Removing and installing

rrectness of i
- 65 A (Valeo version)
l purpos

⇒ page 111
❑ Removing and installing
- 90 A (Bosch version)

nf
ercia

o
⇒ page 115

rm
m

atio
m

4 - V-belt
o

n in
or c

❑ Checking and adjusting

thi
te

V-belt tension

sd
iva

o
r

⇒ page 48
rp

cu
o

m
f

en
ng

❑ V-belt drive for alterna‐ yi

t.
Co
tor and coolant pump . Cop py
⇒ page 46
ht rig
rig ht
py by
Vo
❑ V-belt drive for alterna‐
co lksw
by
cted agen
tor and power assisted Prote AG.
steering vane pump
⇒ page 47
5 - Shim
6 - Washer
7 - Fan gear
❑ Note direction of rota‐
tion, marked by arrow
8 - Alternator
❑ Repairing - 65 A (Valeo
version) ⇒ page 109
❑ Repairing - 90 A (Bosch

9. Alternator with V-belt 45

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

version) ⇒ page 113

9 - Hexagon bolts M8×65
❑ 25 Nm
10 - Hexagon bolt M8×45
❑ 35 Nm
11 - Tensioning arm
❑ with tensioning device
12 - Socket head fastener
❑ Checking and adjusting V-belt tension ⇒ page 48
13 - Bracket
14 - Hexagon bolt M8×70
❑ 25 Nm
15 - Retaining tab
16 - Hexagon bolts M8×30
❑ 16 Nm
17 - Hexagon bolt M8×65
❑ 20 Nm
18 - Hexagon bolt M8×100
❑ 50 Nm

Alternator and coolant pump

1 - Belt pulley - alternator
2 - V-belt
3 - Belt pulley - coolant pump
4 - Belt pulley - crankshaft
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl

pt
du

an
itte

Alternator and coolant pump

y li
erm

ab
ility

1 - Belt pulley - alternator

ot p

wit
, is n

2 - V-belt
h re
hole

spec

3 - Belt pulley - coolant pump

es, in part or in w

t to the co

4 - Belt pulley - crankshaft

rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by

46
co Vo
by lksw
cted
Rep. Gr.27 - Starter, current supply, CCS
agen
Prote AG.
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Alternator and power assisted steering vane pump

1 - Belt pulley - alternator
2 - V-belt
3 - Belt pulley - crankshaft
4 - Belt pulley - coolant pump
5 - V-belt - power assisted steering vane pump
6 - Belt pulley - power assisted steering vane pump

Alternator and power assisted steering vane pump

1 - Belt pulley - alternator
2 - V-belt
AG. Volkswagen AG d
3 - Belt pulley - crankshaft agen oes
olksw not
byV gu
4 - Belt pulley - coolant pump rised ara
nte
ho eo
ut
5 - V-belt - power assisted steering vane
ss a pump ra
c

ce
le

6 - Belt pulley - power assisted steering vane pump

un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

Alternator and power assisted steering vane pump

h re
hole

spec
1 - Belt pulley - power assisted steering vane pump
es, in part or in w

t to the co
2 - V-belt - power assisted steering vane pump
3 - Belt pulley - idler roller

rrectness of i
4 - Belt pulley - alternator
l purpos

5 - V-belt
6 - Belt pulley - crankshaft
nform
mercia

a
com

tion in
r
te o

thi

Alternator, second alternator and power assisted steering vane

s
iva

pump
do
r
rp

cum
fo

1 - Belt pulley - power assisted steering vane pump

en
ng

t.
yi Co
op
2 - V-belt - second alternator C py
ht. rig
rig ht
py by
3 - Belt pulley - alternator co Vo
by lksw
cted agen
Prote
4 - Belt pulley - idler roller
AG.

5 - V-belt
6 - Belt pulley - second alternator
7 - Belt pulley - crankshaft

9. Alternator with V-belt 47

 n AG. Volkswagen AG do
wage es n
Transporter 1991 ➤ , Transporter yV
olks 1996 ➤ ot g
b ua
Electrical system - Editionir se 10.2004
d ran
tee
tho
u or
a ac
Alternator, hydraulic pump and
ss power assisted steering vane
pump

ce
le
un

pt
an
d
itte
1 - Belt pulley - power assisted steering vane pump

y li
erm

ab
ility
2 - V-belt - power assisted steering vane pump and hydraulic ot p

wit
pump
is n

h re
ole,

3 - Belt pulley - idler roller

spec
urposes, in part or in wh

4 - Belt pulley - alternator

t to the co
5 - V-belt

rrectne
6 - Belt pulley - hydraulic pump
7 - Belt pulley - crankshaft

ss o
cial p

f
Alternator, air conditioning compressor and power assisted steer‐

inform
ing vane pump
mer

atio
m

1 - Belt pulley - power assisted steering vane pump

o

n
c

i
or

n
2 - V-belt - power assisted steering vane pump and air condition‐

thi
te

sd
a

ing compressor
iv

o
pr

cum
r
fo

3 - Belt pulley - idler roller

en
ng

t.
yi Co
op
4 - Belt pulley - alternator C py
t. rig
gh ht
yri by
5 - V-belt cop Vo
by lksw
cted agen
Prote
6 - Belt pulley - air conditioner compressor
AG.

7 - Belt pulley - crankshaft

9.3 Checking and adjusting V-belt tension

Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1410-

♦ Socket wrench -3189-

The V-belt tension must be checked between the two belt pulleys
having the greatest distance apart by pressing hard with the

48 Rep. Gr.27 - Starter, current supply, CCS

 AG. Volkswagen AG d
agen oes
olksw not
byV gu
a
rised
Transporter 1991 ➤ra,nTransporter
tee 1996 ➤
o
aut
h
Electrical systemo-r aEdition 10.2004
ss c

ce
e
thumbs; see previous Fig.1 to 8 -arrows-. New V-belt approx. 2

nl

pt
du

an
mm impression depth and used V-belt approx. 5 mm.

itte

y li
erm

ab
– Use torque wrench -V.A.G 1410- and if necessary socket

ility
ot p
wrench -3189- or ring wrench insert -V.A.G 1410/2- to tighten

wit
, is n
securing bolts.

h re
hole

spec
9.3.1 Vehicles with petrol engine
es, in part or in w

t to the co
– Loosen securing bolt -1- for tensioning arm -A- and alternator
at least 1 revolution.

rrectness of i
The alternator must move easily after the securing bolts are loos‐
ened.
l purpos

– Tension V-belt by turning tensioning nut -B- with 8 Nm (new

V-belt) or 4 Nm (used V-belt) and tighten clamping bolt of ten‐

nform
ercia

sioning nut with 35 Nm.

m

at
om

– Tighten alternator securing bolts to bracket with 35 Nm and

ion
c

tighten tensioning arm at lifting eye with 20 Nm.

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
9.3.2 Vehicles with diesel engine Cop py
ht. rig
rig ht
py by
– Loosen all securing bolts for tensioning arm -A- and alternator co Vo
by lksw
cted
at least 1 revolution.
agen
Prote AG.

The alternator must move easily after the securing bolts are loos‐
ened.
– Tension V-belt by turning tensioning nut -B- with 8 Nm (new
V-belt) or 4 Nm (used V-belt) and tighten clamping bolt of ten‐
sioning nut with 35 Nm.
– Tighten alternator securing bolts to bracket with 35 Nm and
tighten tensioning arm at lifting eye with 20 Nm.

9.3.3 Vehicles with 4-cylinder engine and

power assisted steering
– Unscrew hexagon socket head bolts -1-.
– Remove belt pulley halves and adjust V-belt tension by posi‐
tioning more or fewer shims between the belt pulley halves.
Removing shims increases tension, inserting them reduces ten‐
sion.

9.3.4 Vehicles with 5-cylinder engine and

power assisted steering
Special tools and workshop equipment required

9. Alternator with V-belt 49

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

♦ Lever for poly V-belt -VAS 3299-

– Loosen hexagon socket head bolt using offset Allen key (6

mm).
– Turn tensioning roller using pin wrench -a- e.g. V 159/Matra
until required poly V-belt tension is attained.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

50 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

10 Alternator with poly V-belt

10.1 4-cylinder engine with 90 A alternator ▸

04.99

10.1.1 Assembly overview

1 - Bracket
2 - M8 hexagon nut
❑ 30 Nm
3 - Alternator
4 - Voltage regulator
❑ Checking carbon brush‐
es ⇒ page 104 .
❑ Removing and installing
⇒ page 103 .
5 - M4×25 fillister head bolt
with cross-head . Volkswagen AG
gen AG does
swa
6- Protective cap y V olk not
gu
edb ara
nte
7- Hexagon bolts horis
M3 eo
aut ra
8- Poly V-belt
ss c
ce
e
nl

❑ Removing and installing

pt
du

an

⇒ page 51 and
itte

y li
erm

⇒ page 53
ab
ility
ot p

9 - M8 internally threaded
wit
, is n

sleeve
h re
hole

spec

10 - Tensioning spring with

es, in part or in w

guide cap
t to the co

11 - Hexagon bolt M8×39

❑ 25 Nm
rrectness of i

12 - M8×85 hexagon bolts

l purpos

❑ 25 Nm
nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
g

10.1.2 Removing and installing poly V-belt, 4-

n

t.
yi Co
op py
cylinder petrol engine
t. C rig
gh ht
pyri by
Vo
o
by c
– Remove noise insulation tray ⇒ General body repairs, exteri‐
lksw
cted agen
Prote
or; Rep. Gr. 50 ; Body front; Assembly overview - noise
AG.

insulation .

10. Alternator with poly V-belt 51

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Vehicles with belt tension damper

Removing:

Note
n AG. Volkswagen AG do
wage es n
Before removing, mark the top side and direction of rotation y Vof the
olk s ot g
ua
poly V-belt. When installing, ensure correct fitting position ir se
d and
b ran
tee
direction of rotation. If the belt is installed in the wrong
uth position or
o
or
against direction of rotation, the belt will be destroyed!
ss
a ac

ce
le
un

pt
– Clamp commercially available assembly lever between retain‐

an
d
itte

y li
ing lugs -1- and slowly pull in direction of arrow until belt erm

ab
tension damper is so relaxed that poly V-belt can be removed

ility
ot p

from tensioning roller.

wit
is n

h re
ole,

– Loosen top belt tension damper and remove poly V-belt.

spec
urposes, in part or in wh

Installing:

t to the co
Note

rrectne
♦ When fitting used poly V-belts observe the direction of rotation

s
marked on removal!

s o
cial p

f in
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐

form
mer

leys!

atio
om

n
c

– Fit poly V-belt to crankshaft pulley/vibration damper and if

i
or

n thi
e

necessary coolant pump pulley / 2nd alternator belt pulley.

t

sd
iva

o
pr

cum
r
fo

– Install poly V-belt and firmly screw on top belt tension damper.

en
ng

t.
yi Co
op
– Raise tensioning roller with assembly lever and place poly V- C py
t. rig
belt on alternator pulley.
gh ht
pyri by
Vo
co lksw
by
– Lower tensioning roller with assembly lever on poly V-belt. cted agen
Prote AG.

– Start engine and check belt is routed correctly.

Vehicles with tensioning element

Note

Before removing, mark the top side and direction of rotation of the
poly V-belt. When installing, ensure correct fitting position and
direction of rotation. If the belt is installed in the wrong position or
against direction of rotation, the belt will be destroyed!

Special tools and workshop equipment required

♦ Lever for poly V-belt -3299-

52 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Removing:
– Lift tensioning roller with poly V-belt lever -3299- and remove
poly V-belt from alternator belt pulley.
– Remove poly V-belt.
Installing: AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Note rise nte
tho eo
au ra
ss c
♦ When fitting used poly V-belts observe the direction of rotation

ce
e
nl
marked on removal!

pt
du

an
itte

y li
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
erm

ab
leys!

ility
ot p

wit
, is n

h re
– Fit poly V-belt to crankshaft pulley/vibration damper and if
hole

spec
necessary coolant pump pulley / 2nd alternator belt pulley.
es, in part or in w

t to the co
– Lift tensioning roller with poly V-belt lever -3299- and fit poly
V-belt onto alternator belt pulley.

rrectness of i
– Lower tensioning roller onto poly V-belt with poly V-belt lever
-3299- .
l purpos

– Start engine and check belt is routed correctly.

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
op
10.1.3 Removing and installing poly V-belt, 4-
C py
t. rig
gh ht
yri
cylinder diesel engine
p by
co Vo
by lksw
cted agen
Prote AG.
Belt drive without tensioning roller
Special tools and workshop equipment required
♦ Tensioning lever -3297-

Removing:

Note

Before removing, mark the top side and direction of rotation of the
poly V-belt. When installing, ensure correct fitting position and
direction of rotation. If the belt is installed in the wrong position or
against direction of rotation, the belt will be destroyed!

10. Alternator with poly V-belt 53

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004
n AG. Volkswagen AG do
– Unscrew alternator securing bolts -1- and -2- at least one turn. lkswage es n
o ot g
byV ua
ed ran
– Lower alternator with tensioning lever -3297- and remove polyor is tee
V-belt from alternator pulley. auth or
ac
ss
– Removing V-belt for power assisted steering vane pump ⇒

ce
le
un

pt
Running gear, axles, steering from January 1996; Rep. Gr.

an
d
itte
48 ; Repairing power assisted steering .

y li
rm

ab
pe

ility
Installing:

ot

wit
, is n

h re
hole

spec
Note

es, in part or in w

t to the co
♦ When fitting used poly V-belts observe the direction of rotation
marked on removal!

rrectness of i
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
leys! l purpos

– Fit poly V-belt to crankshaft pulley, vibration damper and cool‐

nform
ercia

ant pump pulley.

m

a
– Installing V-belt for power assisted steering vane pump ⇒
com

tion in
Running gear, axles, steering from January 1996; Rep. Gr.
r
te o

48 ; Repairing power assisted steering .

thi
s
iva

do
r

– Lower alternator with tensioning lever -3297- and place poly

rp

cum
fo

V-belt on alternator pulley.

en
ng

t.
yi Co
Cop py
.
– Push alternator down at least 3 times onto stop with tensioning
t rig
gh ht
yri by
lever -3297- to ensure the alternator moves freely. cop Vo
by lksw
cted agen
Prote
– With alternator still detached, allow engine to run at idling
AG.

speed for at least 10 seconds.

– Switch engine off and tighten alternator securing bolts:
– Tighten threaded connections to specified torque settings
⇒ page 120 .
1. Securing bolt -2-
2. Securing bolt -1-

Note

When tightening keep to the following sequence, do not use the

alternator for support and do not touch poly V-belt.

Belt drive with automatic tensioning roller

Special tools and workshop equipment required

♦ Lever for poly V-belt -3299-

54 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Removing:

Note

Before removing, mark the top side and direction of rotation of the
poly V-belt. When installing, ensure correct fitting position and
direction of rotation. If the belt is installed in the wrong position or
against direction of rotation, the belt will be destroyed!

– Lift tensioning roller with poly V-belt lever -3299- and remove
poly V-belt from alternator belt pulley.
– Removing V-belt for power assisted steering vane pump ⇒
Running gear, axles, steering from January 1996; Rep. Gr.
48 ; Repairing power assisted steering .
– Remove poly V-belt.
n AG. Volkswagen AG do
wage
Installing: yV
olks es n
ot g
d b ua
ran
ir se tee
tho
u or
Note ss
a ac

ce
e
nl

pt
du

♦ When fitting used poly V-belts observe the direction of rotation

an
itte

marked on removal!

y li
erm

ab
ility
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
ot p

wit
leys!
, is n

h re
hole

spec
– Fit poly V-belt to crankshaft pulley/vibration damper and cool‐
es, in part or in w

ant pump pulley.

t to the co
– Lift tensioning roller with poly V-belt lever -3299- and fit poly
V-belt onto alternator belt pulley. rrectness of i
l purpos

– Lower tensioning roller onto poly V-belt with poly V-belt lever
-3299- .
nf
ercia

– Installing V-belt for power assisted steering vane pump ⇒

or

Running gear, axles, steering from January 1996; Rep. Gr.

m
m

atio
m

48 ; Repairing power assisted steering .

o

n in
or c

– Start engine and check belt running.

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
10.1.4 Poly V-belt drives pyri by
Vo
co lksw
by
cted agen
Prote
Alternator and power steering vane pump (4-cylinder diesel en‐
AG.

gine)
1 - Belt pulley - alternator
2 - Poly V-belt - alternator, coolant pump and crankshaft
3 - Belt pulley - coolant pump
4 - V-belt - crankshaft and power steering vane pump
5 - Belt pulley - power assisted steering vane pump
6 - Belt pulley - crankshaft

10. Alternator with poly V-belt 55

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Alternator and power assisted steering vane pump (4-cylinder

petrol engine)
1 - Belt pulley - alternator
2 - Poly V-belt
3 - Belt pulley - power assisted steering vane pump
4 - Belt pulley - crankshaft
5 - Idler roller
6 - Tensioning roller

10.2 4-cylinder engine with 90 A alternator

05.99 ▸

10.2.1 Assembly overview

1 - Hexagon bolt M8×85

❑ 25 Nm
2 - Bracket
n AG. Volkswagen AG do
wage es n
3 - M8 hexagon nut yV
olks ot g
ua
d b ran
❑ 30 Nm o
ir se tee
th or
u
4 - Cross-head screws ss
a ac
ce
le

5 - Hexagon nut
un

pt
an
d
itte

y li

❑ M8
rm

ab
pe

ility

6 - Hexagon nut
ot

wit
, is n

❑ M8
h re
hole

spec

7 - Cross-head screw
es, in part or in w

t to the co

8 - Voltage regulator
❑ Removing and installing
⇒ page 105 .
rrectness of i

❑ Checking carbon brush‐

l purpos

es ⇒ page 106 .
9 - Protective cap
nform
ercia

10 - Alternator
m

a
com

tio

11 - Poly V-belt
n in
r
te o

❑ Removing and installing

thi
s
iva

⇒ page 57 and
do
r
rp

⇒ page 58
um
fo

en
g

❑ Poly V-belt drives

n

t.
yi Co
op
⇒ page 61 and C py
t. rig
⇒ page 61
gh ht
pyri by
Vo
co lksw
by
12 - Internally threaded sleeve cted agen
Prote AG.
M8
13 - Tensioning spring with
guide cap
14 - Hexagon bolt M8×39
❑ 25 Nm

56 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

10.2.2 Removing and installing poly V-belt, 4-

AG. Volkswagen AG d
agen
by
cylinder
Vol
ksw
petrol engine oes
not
gu
ara
ed n
– Remove
tho
ris noise insulation tray ⇒ General body repairs,
tee
or
exteri‐
or;
s au Rep. Gr. 50 ; Body front; Assembly overview noise
ac insu‐
lation
s
.

ce
le
un

pt
Vehicles with belt tension damper

an
d
itte

y li
erm

ab
Removing:

ility
ot p

wit
is n

h re
ole,

Note

spec
urposes, in part or in wh

t to the co
Before removing, mark the top side and direction of rotation of the
poly V-belt. When installing, ensure correct fitting position and
direction of rotation. If the belt is installed in the wrong position or

rrectne
against direction of rotation, the belt will be destroyed!

s
– Clamp commercially available assembly lever between retain‐

s o
ing lugs -1- and slowly pull in direction of arrow until belt
cial p

f in
tension damper is so relaxed that poly V-belt can be removed

form
mer

from tensioning roller.

atio
m

– Loosen top belt tension damper and remove poly V-belt.

o

n
c

i
or

n thi
e

Installing:
t

sd
iva

o
pr

cum
r
fo

en
ng

Note
t.
yi Co
Cop py
t. rig
gh ht
♦ When fitting used poly V-belts observe the direction of rotation
pyri by
Vo
o
marked on removal!
c by lksw
cted agen
Prote AG.
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
leys!

– Fit poly V-belt to crankshaft pulley/vibration damper and if

necessary coolant pump pulley / 2nd alternator belt pulley.

– Install poly V-belt and firmly screw on top belt tension damper.
– Raise tensioning roller with assembly lever and place poly V-
belt on alternator pulley.
– Lower tensioning roller with assembly lever on poly V-belt.
– Start engine and check belt running.
Vehicles with tensioning element

Special tools and workshop equipment required

10. Alternator with poly V-belt 57

 AG. Volkswagen AG d
agen oes
ksw n
Transporterby1991 Vol
➤ , Transporter 1996 ➤ ot gua
d ran
Electrical oris system - Edition 10.2004
e
tee
h
aut or
ac
s
♦ Lever fors poly V-belt -3299-

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
Removing:
cial p

f inform
mer

atio
m

Note
o

n
c

i
or

n thi
e

Before removing, mark the top side and direction of rotation of the
t

sd
va

poly V-belt. When installing, ensure correct fitting position and

i

o
pr

cum
r

direction of rotation. If the belt is installed in the wrong position or

fo

en
ng

against direction of rotation, the belt will be destroyed!

t.
yi Co
Cop py
t. rig
gh ht
yri
– Lift tensioning roller with poly V-belt lever -3299- and remove p by
co Vo
poly V-belt from alternator belt pulley.
by lksw
cted agen
Prote AG.
– Remove poly V-belt.
Installing:

Note

♦ When fitting used poly V-belts observe the direction of rotation

marked on removal!
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
leys!

– Fit poly V-belt to crankshaft pulley/vibration damper and if

necessary coolant pump pulley / 2nd alternator belt pulley.

– Lift tensioning roller with poly V-belt lever -3299- and fit poly
V-belt onto alternator belt pulley.
– Lower tensioning roller onto poly V-belt with poly V-belt lever
-3299- .
– Start engine and check belt running.

10.2.3 Removing and installing poly V-belt, 4-

cylinder diesel engine
Belt drive without tensioning roller
Special tools and workshop equipment required

58 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

♦ Tensioning lever -3297-

Removing:
AG. Volkswagen AG d
agen oes
o lksw not
y V gu
Note ise
d b ara
nte
or eo
th
u ra
Before removing,
ss a
mark the top side and direction of rotation of the
c
poly V-belt. When installing, ensure correct fitting position and

ce
e
nl

pt
du

direction of rotation. If the belt is installed in the wrong position or

an
itte

against direction of rotation, the belt will be destroyed!

y li
erm

ab
ility
ot p

– Unscrew alternator securing bolts -1- and -2- at least one turn.

wit
, is n

h re
hole

– Lower alternator with tensioning lever -3297- and remove poly

spec
V-belt from alternator pulley.
es, in part or in w

– Removing V-belt for power assisted steering vane pump ⇒ t to the co

Running gear, axles, steering from January 1996; Rep. Gr.
48 ; Repairing power assisted steering .
rrectness of i

Installing:
l purpos

nform

Note
mercia

at

♦ When fitting used poly V-belts observe the direction of rotation

om

ion

marked on removal!
c

in t
or

his
te

♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
a

do
riv

leys!
p

cum
for

en
ng

t.
yi Co
– Fit poly V-belt to crankshaft pulley, vibration damper and cool‐ Cop py
t. rig
ant pump pulley. opyri
gh by
Vo
ht
c lksw
– Installing V-belt for power assisted steering vane pump ⇒
by
cted agen
Prote
Running gear, axles, steering from January 1996; Rep. Gr.
AG.

48 ; Repairing power assisted steering .

– Lower alternator with tensioning lever -3297- and place poly
V-belt on alternator pulley.

10. Alternator with poly V-belt 59

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Push alternator down at least 3 times onto stop with tensioning

lever -3297- to ensure the alternator moves freely.
– With alternator still detached, allow engine to run at idling
speed for at least 10 seconds.
– Switch off engine and tighten alternator securing bolts:
– Tighten threaded connections to specified torque settings
⇒ page 120 .
1. Securing bolt -2-
2. Securing bolt -1-

Note
. Volkswagen AG
gen AG d
When tightening keep to the following
Vol
ksw sequence, do not use
a oes
nothe
t gu
alternator for support and sdo
ed bnot touch poly V-belt.
y ara
n
ri tee
ho
ut or
Belt drive with automatic
ss
a
tensioning roller ac

ce
e
nl

pt
du

an
Special tools and workshop equipment required
itte

y li
erm

ab
♦ Lever for poly V-belt -3299-

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
m

Removing:
o

n in
or c

thi
te

sd
iva

o
r

Note
rp

cu
o

m
f

en
ng

t.
yi
Before removing, mark the top side and direction of rotation of the
Co
Cop py
poly V-belt. When installing, ensure correct fitting position and
t. rig
gh ht
yri
direction of rotation. If the belt is installed in the wrong position or
p by
co Vo
by lksw
against direction of rotation, the belt will be destroyed! Prote
cted AG.
agen

60 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Lift tensioning roller with poly V-belt lever -3299- and remove
poly V-belt from alternator belt pulley.
– Removing V-belt for power assisted steering vane pump ⇒
Running gear, axles, steering from January 1996; Rep. Gr.
48 ; Repairing power assisted steering .
– Remove poly V-belt.
Installing:
AG. Volkswagen AG d
agen oes
lksw not
Note d by
Vo gu
ara
ise nte
or eo
h
♦ When fitting
s aut used poly V-belts observe the direction of rotation
ra
c
marked
s on removal!

ce
le
un

pt
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐

an
d
itte

y li
leys!
rm

ab
pe

ility
ot

wit
– Fit poly V-belt to crankshaft pulley/vibration damper and cool‐
, is n

h re
ant pump pulley.
hole

spec
es, in part or in w

– Lift tensioning roller with poly V-belt lever -3299- and fit poly

t to the co
V-belt onto alternator belt pulley.
– Lower tensioning roller onto poly V-belt with poly V-belt lever

rrectness of i
-3299- .
l purpos

– Installing V-belt for power assisted steering vane pump ⇒

Running gear, axles, steering from January 1996; Rep. Gr.
48 ; Repairing power assisted steering .
nform
ercia

– Start engine and check belt running.

m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
g

10.2.4 Poly V-belt drives

n

t.
yi Co
Cop py
t. rig
Alternator and power steering vane pump (4-cylinder diesel en‐
gh ht
yri by
gine)
op Vo
by c lksw
cted agen
Prote AG.
1 - Belt pulley - alternator
2 - Poly V-belt - alternator, coolant pump and crankshaft
3 - Belt pulley - coolant pump
4 - V-belt - crankshaft and power assisted steering vane pump
5 - Belt pulley - power assisted steering vane pump
6 - Belt pulley - crankshaft

Alternator and power assisted steering vane pump (4-cylinder

petrol engine)
1 - Belt pulley - alternator
2 - Poly V-belt
3 - Belt pulley - power assisted steering vane pump
4 - Belt pulley - crankshaft
5 - Idler roller
6 - Tensioning roller

10. Alternator with poly V-belt 61

 AG. Volkswagen AG d
agen oes
Transporter 1991 ➤ , TransporterV1996 olks ➤
w not
gu
by
Electrical system - Edition 10.2004
ris
ed ara
nte
tho eo
au ra
10.3 4-cylinder engine with 120 A alternator ss c

ce
le
▸ 04.99

un

pt
an
d
itte

y li
rm

ab
pe

ility
ot
10.3.1 Assembly overview

wit
, is n

h re
hole

spec
es, in part or in w

1 - Hexagon bolt M8

t to the co
❑ 25 Nm
2 - Tensioning roller

rrectness of i
3 - Protective cap
l purpos

4 - Tensioning lever

nform
ercia

5 - Dust cap
m

6 - Bracket

a
com

tion in
7 - Dust cap
r
te o

thi
s
iva

8 - Tensioning element

do
r
rp

cum
fo

9 - Hexagon socket head bolt

en
ng

t.
yi Co
❑ 25 Nm Cop py
t. rig
gh
❑ M8×16
ht
pyri by
Vo
co lksw
by
cted
10 - Hexagon socket head bolt
agen
Prote AG.

❑ 25 Nm
❑ M8×22
11 - Hexagon bolts M3
12 - Protective cap
13 - Fillister head bolts with
cross head M4×25
14 - Voltage regulator
❑ Removing and installing
⇒ page 103 .
❑ Checking carbon brush‐
es ⇒ page 104 .
15 - Alternator
16 - Poly V-belt
❑ Removing and installing
⇒ page 62 and
⇒ page 64
❑ Poly V-belt drives ⇒ page 67 and ⇒ page 67 .
17 - Hexagon bolts M8×85
❑ 25 Nm

10.3.2 Removing and installing poly V-belt, 4-

cylinder petrol engine
– Remove noise insulation tray ⇒ General body repairs, exteri‐
or; Rep. Gr. 50 ; Body front; Assembly overview - noise
insulation .

62 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Vehicles with belt tension damper

Removing:

Note

Before removing, mark the top side and direction of rotation of the
poly V-belt. When installing, ensure correct fitting position and
direction of rotation. If the belt is installed in the wrong position or
against direction of rotation, the belt will be destroyed!

– Clamp commercially available assembly lever between retain‐

ing lugs -1- and slowly pull in direction of arrow until belt
tension damper is so relaxed that poly V-belt can be removed
from tensioning roller.
– Loosen top belt tension damper and remove poly V-belt.
Installing:

Note

♦ When fitting used poly V-belts observe the direction of rotation

marked on removal!
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
leys!

– Fit poly V-belt to crankshaft pulley/vibration damper and if

necessary coolant pump pulley / 2nd alternator-belt pulley.

– Install poly V-belt and firmly screw on top belt tension damper.
– Raise tensioning roller with assembly lever and place poly V-
belt on alternator pulley.
– Lower tensioning roller with assembly lever on poly V-belt.
. Volkswagen AG
gen AG does
– Start engine and check
Vol
ksw
a
belt running. not
y gu
db ara
Vehicles withoritensioning
se element nte
eo
th
au ra
c
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

Special tools and workshop equipment required

wit
, is n

h re

♦ Poly V-belt lever -3299-

hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co

63
by lksw
cted agen
Prote 10. Alternator with poly V-belt
AG.
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Removing:

Note

Before removing, mark the top side and direction of rotation of the
poly V-belt. When installing, ensure correct fitting position and
direction of rotation. If the belt is installed in the wrong position or
against direction of rotation, the belt will be destroyed!

– Lift tensioning roller with poly V-belt lever -3299- and remove
poly V-belt from alternator belt pulley.
– Remove poly V-belt.
Installing:

Note

♦ When fitting used poly V-belts observe the direction of rotation

marked on removal! agen
AG. Volkswagen AG d
oes
olksw not
yV
♦ When fitting belt, ed ensure that poly V-belt seats correctly
b gu
ara in pul‐
leys! ris nte
ho eo
aut ra
ss c
– Fit poly V-belt to crankshaft pulley/vibration damper and if
ce
le
un

pt

necessary coolant pump pulley / 2nd alternator-belt pulley.

an
d
itte

y li
rm

ab
pe

– Lift tensioning roller with poly V-belt lever -3299- and fit poly
ility
ot

V-belt onto alternator belt pulley.

wit
, is n

h re

– Lower tensioning roller onto poly V-belt with poly V-belt lever
hole

spec

-3299- .
es, in part or in w

t to the co

– Start engine and check belt running.

rrectness of i
l purpos

nform
mercia

a
com

ti

10.3.3 Removing and installing poly V-belt, 4-

on in
r
te o

cylinder diesel engine

thi
s
iva

do
r
rp

Belt drive without tensioning roller

um
fo

en
ng

t.
yi
Special tools and workshop equipment required
Co
Cop py
ht. rig
♦ Tensioning lever -3297- rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

64 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Removing:

Note

Before removing, mark the top side and direction of rotation of the
poly V-belt. When installing, ensure correct fitting position and
direction of rotation. If the belt is installed in the wrong position or
against direction of rotation, the belt will be destroyed!
n AG. Volkswagen AG do
swage es n
– Unscrew alternator securing bolts -1- b and
yV
o -2- at least one turn.
lk ot g
ua
d ran
ir se
– Lower alternator with tensioning th lever -3297- and remove poly
o tee
or
V-belt from alternator pulley.
ss
au ac

ce
le

– Removing V-belt for power assisted steering vane pump ⇒

un

pt
an
Running gear, axles, steering from January 1996; Rep. Gr.
d
itte

y li
48 ; Repairing power assisted steering .
erm

ab
ility
ot p

Installing:

wit
is n

h re
ole,

spec
urposes, in part or in wh

Note

t to the co
♦ When fitting used poly V-belts observe the direction of rotation
marked on removal!

rrectne
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
leys!

ss o
cial p

f i
– Fit poly V-belt to crankshaft pulley, vibration damper and cool‐

nform
ant pump pulley.
mer

atio
m

– Installing V-belt for power assisted steering vane pump ⇒

o

n
c

i
Running gear, axles, steering from January 1996; Rep. Gr.
or

n thi
e

48 ; Repairing power assisted steering .

t

sd
iva

o
pr

c
– Lower alternator with tensioning lever -3297- and place poly
um
r
fo

en
ng

V-belt on alternator pulley.

t.
yi Co
Cop py
t. rig
gh
– Push alternator down at least 3 times onto stop with tensioning
ht
pyri by
Vo
lever -3297- to ensure the alternator moves freely.
co lksw
by
cted agen
Prote AG.
– With alternator still detached, allow engine to run at idling
speed for at least 10 seconds.
– Switch off engine and tighten alternator securing bolts.
– Tighten threaded connections to specified torque settings
⇒ page 120 .
1. Securing bolt -2-
2. Securing bolt -1-

Note

When tightening keep to the following sequence, do not use the

alternator for support and do not touch poly V-belt.

Belt drive with automatic tensioning roller

Special tools and workshop equipment required

10. Alternator with poly V-belt 65

 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Transporter 1991 ➤ , Transporter 1996 ➤ ut
ho eo
ra
a
Electrical system - Edition 10.2004 ss c

ce
le
un

pt
♦ Poly V-belt lever -3299-

an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
Removing: mercia

a
com

tion in
r
te o
Note

thi
s
iva

do
r
rp

c
Before removing, mark the top side and direction of rotation of the

um
fo

en
g

poly V-belt. When installing, ensure correct fitting position and

n

t.
yi Co
direction of rotation. If the belt is installed in the wrong position or Cop py
. rig
against direction of rotation, the belt will be destroyed!
ht ht
rig by
copy Vo
by lksw
cted agen
– Lift tensioning roller with poly V-belt lever -3299- and remove Prote AG.
poly V-belt from alternator belt pulley.
– Removing V-belt for power assisted steering vane pump ⇒
Running gear, axles, steering from January 1996; Rep. Gr.
48 ; Repairing power assisted steering .
– Remove poly V-belt.
Installing:

Note

♦ When fitting used poly V-belts observe the direction of rotation

marked on removal!
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
leys!

– Fit poly V-belt to crankshaft pulley/vibration damper and cool‐

ant pump pulley.

– Lift tensioning roller with poly V-belt lever -3299- and fit poly
V-belt onto alternator belt pulley.
– Lower tensioning roller onto poly V-belt with poly V-belt lever
-3299- .
– Installing V-belt for power assisted steering vane pump ⇒
Running gear, axles, steering from January 1996; Rep. Gr.
48 ; Repairing power assisted steering .
– Start engine and check belt running.

66 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

10.3.4 Poly V-belt drives

Alternator and power steering vane pump (4-cylinder diesel en‐
gine)
1 - Belt pulley - alternator
2 - Poly V-belt - alternator, coolant pump and crankshaft
3 - Belt pulley - coolant pump
4 - V-belt - crankshaft and power assisted steering vane pump
5 - Belt pulley - power assisted steering vane pump
6 - Belt pulley - crankshaft

Alternator and power assisted steering vane pump (4-cylinder

petrol engine)
1 - Belt pulley - alternator
2 - Poly V-belt
3 - Belt pulley - power assisted steering vane pump
4 - Belt pulley - crankshaft
5 - Idler roller
6 - Tensioning roller
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
10.4 4-cylinder engine with 120 A alternator ise nte
or eo
h
ut ra
05.99 ▸ ss a c

ce
e
nl

pt
du

an
itte

y li
10.4.1 Assembly overview
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

10. Alternator with poly V-belt 67

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1 - Hexagon bolt M8
❑ 25 Nm
2 - Tensioning roller
3 - Protective cap
4 - Tensioning lever
5 - Dust cap
6 - Bracket
7 - Dust cap
8 - Tensioning element
AG. Volkswagen AG d
agen
9 - Hexagon socket head bolt Volksw
oes
not
gu
by ara
❑ 25 Nm rised
nte
ho eo
❑ M8×16 aut ra
c
ss
10 - Hexagon socket head bolt

ce
e
nl

pt
du

an
❑ 25 Nm
itte

y li
erm

ab
❑ M8×22 mm

ility
ot p

wit
11 - Cross-head screws
, is n

h re
hole

12 - Hexagon nut

spec
es, in part or in w

❑ M8

t to the co
13 - Hexagon nut
❑ M8

rrectness of i
14 - Cross-head screw
l purpos

15 - Voltage regulator

nf
ercia

Removing and installing

or
⇒ page 105 .

m
m

atio
om

n in
Checking carbon brushes
or c

⇒ page 106 .
thi
te

sd
iva

o
r
rp

cu

16 - Protective cap
o

m
f

en
ng

t.
yi
17 - Alternator
Co
Cop py
t. rig
18 - Poly V-belt
gh ht
pyri by
Vo
o
by c
❑ Removing and installing ⇒ page 68 and ⇒ page 70
lksw
cted agen
Prote AG.
❑ Poly V-belt drives ⇒ page 73
19 - Hexagon bolts M8×85
❑ 25 Nm

10.4.2 Removing and installing poly V-belt, 4-

cylinder petrol engine
– Remove noise insulation tray ⇒ General body repairs, exteri‐
or; Rep. Gr. 50 ; Body front; Assembly overview - noise
insulation .

68 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Vehicles with belt tension damper

Removing:

Note

Before removing, mark the top side and direction of rotation of the
poly V-belt. When installing, ensure correct fitting position and
direction of rotation. If the belt is installed in the wrong position or
against direction of rotation, the belt will be destroyed!

– Clamp commercially available assembly lever between retain‐

ing lugs -1- and slowly pull in direction of arrow until belt
tension damper is so relaxed that poly V-belt can be removed
from tensioning roller. . Volkswagen AG
gen AG does
swa
– Loosen top belt tension damper and remove poly V-belt.
by
Vol
k not
gu
ara
ed nte
Installing: oris eo
th
au ra
c
ss

ce
le
un

Note

pt
an
d
itte

y li
rm

ab
♦ When fitting used poly V-belts observe the direction of rotation
pe

ility
marked on removal!
ot

wit
, is n

h re
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
hole

spec
leys!
es, in part or in w

t to the co
– Fit poly V-belt to crankshaft pulley/vibration damper and if
necessary coolant pump pulley / 2nd alternator-belt pulley.

rrectness of i
– Install poly V-belt and firmly screw on top belt tension damper.
l purpos

– Raise tensioning roller with assembly lever and place poly V-

belt on alternator pulley.

nform
ercia

– Lower tensioning roller with assembly lever on poly V-belt.

m

a
com

tio
– Start engine and check belt running.

n in
r
te o

thi
Vehicles with tensioning element

s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Special tools and workshop equipment required Prote AG.

♦ Poly V-belt lever -3299-

10. Alternator with poly V-belt 69

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Removing:

Note

Before removing, mark the top side and direction of rotation of the
poly V-belt. When installing, ensure correct fitting position and
direction of rotation. If the belt is installed in the wrong position or
against direction of rotation, the belt will be destroyed!

– Lift tensioning roller with poly V-belt lever -3299- and remove
poly V-belt from alternator belt pulley.
– Remove poly V-belt.
Installing:

Note

♦ When fitting used poly V-belts observe the direction of rotation

marked on removal! agen
AG. Volkswagen AG d
oes
lksw not
When fitting belt, ensure that poly V-belt seats correctly in pul‐d by V
o
♦ gu
ara
leys! orise nte
eo
h
aut ra
ss c
– Fit poly V-belt to crankshaft pulley/vibration damper and if

ce
le
un

necessary coolant pump pulley / 2nd alternator-belt pulley.

pt
an
d
itte

y li
erm

ab
– Lift tensioning roller with poly V-belt lever -3299- and fit poly

ility
ot p

V-belt onto alternator belt pulley.

wit
is n

h re
– Lower tensioning roller onto poly V-belt with poly V-belt lever
ole,

spec
-3299- .
urposes, in part or in wh

t to the co
– Start engine and check belt running.

rrectness o
cial p

f inform
mer

atio
m

10.4.3 Removing and installing poly V-belt, 4-

o

n
c

i
or

n
cylinder diesel engine
thi
te

sd
iva

o
r

Belt drive without tensioning roller

p

cum
r
fo

en
ng

Special tools and workshop equipment required

t.
yi Co
Cop py
t. rig
♦ Tensioning lever -3297- opyri
gh by
Vo
ht
by c lksw
cted agen
Prote AG.

70 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Removing:

Note

Before removing, mark the top side and direction of rotation of the
poly V-belt. When installing, ensure correct fitting position and
direction of rotation. If the belt is installed in the wrong position or
against direction of rotation, the belt will be destroyed!

– Unscrew alternator securing bolts -1- and -2- at least one turn.
– Lower alternator with tensioning lever -3297- and remove poly
V-belt from alternator pulley.
– Removing V-belt for power assisted steering vane pump ⇒
Running gear, axles, steering from January 1996; Rep. Gr.
48 ; Repairing power assisted steering .
AG. Volkswagen AG d
agen
Installing: Volksw
oes
not
gu
by ara
d
rise nte
tho eo
Note ss au ra
c

ce
e
nl

pt
♦ When fitting used poly V-belts observe the direction of rotation
du

an
itte

marked on removal!

y li
erm

ab
ility
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
ot p

wit
leys!
, is n

h re
hole

spec
– Fit poly V-belt to crankshaft pulley, vibration damper and cool‐
es, in part or in w

ant pump pulley.

t to the co
– Installing V-belt for power assisted steering vane pump ⇒
Running gear, axles, steering from January 1996; Rep. Gr.
rrectness of i

48 ; Repairing power assisted steering .

l purpos

– Lower alternator with tensioning lever -3297- and place poly

V-belt on alternator pulley.
nform
ercia

– Push alternator down at least 3 times onto stop with tensioning

m

at

lever -3297- to ensure the alternator moves freely.

om

ion
c

in t
r

– With alternator still detached, allow engine to run at idling

o

his
te

speed for at least 10 seconds.

a

do
priv

cum
or

– Switch off engine and tighten alternator securing bolts.

f

en
ng

t.
yi Co
– Tighten threaded connections to specified torque settings t. Cop py
⇒ page 120 .
rig
gh ht
pyri by
Vo
co
1. Securing bolt -2-
by lksw
cted agen
Prote AG.
2. Securing bolt -1-

Note

When tightening keep to the following sequence, do not use the

alternator for support and do not touch poly V-belt.

Belt drive with automatic tensioning roller

Special tools and workshop equipment required

10. Alternator with poly V-belt 71

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

♦ Poly V-belt lever -3299-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
Removing:
itte

y li
erm

ab
ility
ot p

Note

wit
, is n

h re
hole

spec
Before removing, mark the top side and direction of rotation of the
es, in part or in w

poly V-belt. When installing, ensure correct fitting position and

t to the co
direction of rotation. If the belt is installed in the wrong position or
against direction of rotation, the belt will be destroyed!

rrectness of i
– Lift tensioning roller with poly V-belt lever -3299- and remove
l purpos

poly V-belt from alternator belt pulley.

– Removing V-belt for power assisted steering vane pump ⇒

nf
ercia

Running gear, axles, steering from January 1996; Rep. Gr.

or
48 ; Repairing power assisted steering .

m
m

atio
m

– Remove poly V-belt.

o

n in
or c

thi
e

Installing:
t

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
Note Cop
yi Co
py
t. rig
gh ht
♦ When fitting used poly V-belts observe the direction of rotation pyri by
Vo
co
marked on removal!
by lksw
cted agen
Prote AG.
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
leys!

– Fit poly V-belt to crankshaft pulley/vibration damper and cool‐

ant pump pulley.

– Lift tensioning roller with poly V-belt lever -3299- and fit poly
V-belt onto alternator belt pulley.
– Lower tensioning roller onto poly V-belt with poly V-belt lever
-3299- .
– Installing V-belt for power assisted steering vane pump ⇒
Running gear, axles, steering from January 1996; Rep. Gr.
48 ; Repairing power assisted steering .
– Start engine and check belt running.

72 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
n AG. Volkswagen AG do Electrical system - Edition 10.2004
lkswage es n
o ot g
yV ua
10.4.4 Poly V-belt drives
d b ran
ir se tee
tho
u or
Alternator
ss and power steering vane pump (4-cylinder diesel cen‐
a a
gine)

ce
le
un

pt
an
d

1 - Belt pulley - alternator

itte

y li
rm

ab
pe

2 - Poly V-belt - alternator, coolant pump and crankshaft

ility
ot

wit
, is n

3 - Belt pulley - coolant pump

h re
hole

spec
4 - V-belt - crankshaft and power assisted steering vane pump
es, in part or in w

t to the co
5 - Belt pulley - power assisted steering vane pump
6 - Belt pulley - crankshaft

rrectness of i
Alternator and power assisted steering vane pump (4-cylinder
l purpos

petrol engine)
1 - Belt pulley - alternator

nform
ercia

2 - Poly V-belt
m

a
com

tio
3 - Belt pulley - power assisted steering vane pump

n in
r
te o

thi
4 - Belt pulley - crankshaft

s
iva

do
r
rp

c
5 - Idler roller
um
fo

en
ng

t.
yi
6 - Tensioning roller
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
10.5 4-cylinder engine with air conditioner
Prote AG.

compressor or 2nd alternator ▸ 04.99

10.5.1 Assembly overview

10. Alternator with poly V-belt 73

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1 - Hexagon bolt M8×48

❑ 25 Nm
2 - Bush 30 x 18 x 10
3 - Hexagon collared bolts
M8×25 agen
AG. Volkswagen AG d
oes
lksw not
❑ 25 Nm d by
Vo gu
ara
ise nte
r
4 - Bracket ut
ho eo
ra
s a c
5 - Bracket for alternator and s

ce
e
nl

air conditioner compressor or

pt
du

an
2nd alternator
itte

y li
erm

ab
6 - Self-locking hexagon nut

ility
ot p

M8

wit
, is n

h re
❑ 33 Nm
hole

spec
❑ Always renew.
es, in part or in w

t to the co
7 - Hexagon bolts M3
8 - Protective cap

rrectness of i
9 - Fillister head bolts with
l purpos

cross head M4×25

10 - Voltage regulator

nform
ercia

❑ Checking carbon brush‐

es ⇒ page 104 .
m

at
om

io
❑ Removing and installing

n
c

in t
or

⇒ page 103 .

his
ate

do
riv

11 - Alternator
p

cum
for

en
g

12 - Poly V-belt
n

t.
yi Co
op
❑ Removing and installing
C py
t. rig
gh
⇒ page 74 and
ht
pyri by
Vo
o
⇒ page 76 by c lksw
cted agen
Prote AG.
❑ Poly V-belt drives
⇒ page 79 and
⇒ page 79
13 - Hexagon bolt M8×92
❑ 25 Nm
14 - Stud bolts with hexagon M8×55 / M8×51
❑ 25 Nm
Remain fitted when removing

10.5.2 Removing and installing poly V-belt, 4-

cylinder petrol engine
– Remove noise insulation tray ⇒ General body repairs, exteri‐
or; Rep. Gr. 50 ; Body front; Assembly overview - noise
insulation .

74 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Vehicles with belt tension damper

Removing:

Note

Before removing, mark the top side and direction of rotation of the
poly V-belt. When installing, ensure correct fitting position and
direction of rotation. If the belt is installed in the wrong position or
against direction of rotation, the belt will be destroyed!

– Clamp commercially available assembly lever between retain‐

ing lugs -1- and slowly pull in direction of arrow until belt
tension damper is so relaxed that poly V-belt can be removed
from tensioning roller.
– Loosen top belt tension damper and remove poly V-belt.
Installing:

Note

♦ When fitting used poly V-belts observe the direction of rotation

marked on removal!
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
leys!

– Fit poly V-belt to crankshaft pulley/vibration damper and if

necessary coolant pump pulley / 2nd alternator-belt pulley.

– Install poly V-belt and firmly screw on top belt tension damper.
Volkswa
– Raise tensioning roller with assembly
agenlever and place
AG. gen AG
poly
does V-
ksw
belt on alternator pulley. by Vol not
gu
a d ran
ise
– Lower tensioning rollerthowith
r assembly lever on poly V-belt. tee
or
u ac
sa
– Start engine and check
s belt running.
ce
e
nl

pt
du

Vehicles with tensioning element

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

Special tools and workshop equipment required

t to the co

♦ Poly V-belt lever -3299-

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

10. Alternator with poly V-belt 75

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Removing:

Note

Before removing, mark the top side and direction of rotation of the
poly V-belt. When installing, ensure correct fitting position and
direction of rotation. If the belt is installed in theagwrong
en AG. Vposition
olkswagenorAG
does
against direction of rotation, the belt will ybe
V olkdestroyed!
sw not
g
b ua
ed ran
oris tee
– Lift tensioning roller with polyauV-belt
th lever -3299- and remove or
ac
poly V-belt from alternator belt
ss pulley.

ce
e
nl

pt
– Remove poly V-belt.
du

an
itte

y li
Installing:
erm

ab
ility
ot p

wit
, is n

h re
Note
hole

spec
es, in part or in w

♦ When fitting used poly V-belts observe the direction of rotation

t to the co
marked on removal!
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐

rrectness of i
leys!
l purpos

– Fit poly V-belt to crankshaft pulley/vibration damper and if

necessary coolant pump pulley / 2nd alternator-belt pulley.

nform
mercia

– Lift tensioning roller with poly V-belt lever -3299- and fit poly

at
om

io
V-belt onto alternator belt pulley.

n
c

in t
or

– Lower tensioning roller onto poly V-belt with poly V-belt lever
his
ate

do
riv

-3299- .
p

cum
for

– Start engine and check belt running.

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

10.5.3 Removing and installing poly V-belt, 4-

cylinder diesel engine
Belt drive without tensioning roller
Special tools and workshop equipment required
♦ Tensioning lever -3297-

76 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004
AG. Volkswagen AG d
Removing: ksw
agen oes
not
Vol
by gu
d ara
rise nte
o eo
Noteauth
ra
ss c

ce
le

Before removing, mark the top side and direction of rotation of the
un

pt
an
d

poly V-belt. When installing, ensure correct fitting position and

itte

y li
direction of rotation. If the belt is installed in the wrong position or
erm

ab
against direction of rotation, the belt will be destroyed!

ility
ot p

wit
is n

h re
– Unscrew alternator securing bolts -1- and -2- at least one turn.
ole,

spec
urposes, in part or in wh

– Lower alternator with tensioning lever -3297- and remove poly

t to the co
V-belt from alternator pulley.
– Removing V-belt for power assisted steering vane pump ⇒
Running gear, axles, steering from January 1996; Rep. Gr.

rrectne
48 ; Repairing power assisted steering .

s
Installing:

s o
cial p

f inform
mer

Note

atio
om

n
c

i
♦ When fitting used poly V-belts observe the direction of rotation
or

n thi
e

marked on removal!
t

sd
iva

o
pr

c
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
um
r
fo

en
ng

leys!
t.
yi Co
Cop py
t. rig
gh
– Fit poly V-belt to crankshaft pulley, vibration damper and cool‐
ht
pyri by
Vo
o
ant pump pulley.
c by lksw
cted agen
Prote AG.
– Installing V-belt for power assisted steering vane pump ⇒
Running gear, axles, steering from January 1996; Rep. Gr.
48 ; Repairing power assisted steering .
– Lower alternator with tensioning lever -3297- and place poly
V-belt on alternator pulley.

– Push alternator down at least 3 times onto stop with tensioning

lever -3297- to ensure the alternator moves freely.
– With alternator still detached, allow engine to run at idling
speed for at least 10 seconds.
– Switch off engine and tighten alternator securing bolts.
– Tighten threaded connections to specified torque settings
⇒ page 120 .
1. Securing bolt -2-
2. Securing bolt -1-

Note

When tightening keep to the following sequence, do not use the

alternator for support and do not touch poly V-belt.

Belt drive with automatic tensioning roller

Special tools and workshop equipment required

10. Alternator with poly V-belt 77

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

♦ Poly V-belt lever -3299-

Removing:

Note

Before removing, mark the top side and direction of rotation of the
poly V-belt. When installing, ensure correct fitting position and
direction of rotation. If the belt is installed in the wrong position or
against direction of rotation, the belt will be destroyed!

– Lift tensioning roller with poly V-belt lever -3299- and remove
poly V-belt from alternator belt pulley.
– Removing V-belt for power assisted steering vane pump ⇒
Running gear, axles, steering from January 1996; Rep. Gr.
48 ; Repairing power assisted steering .
– Remove poly V-belt.
Installing:

Note
. Volkswagen AG
gen AG does
♦ When fitting used poly V-belts observe the direction ofVorotation
lksw
a
not
marked on removal! d by gu
ara
rise nte
o eo
♦ When fitting belt, ensure that poly V-belt seats
aut correctly in pul‐
h
ra
leys! ss c
ce
le
un

pt
an
d

– Fit poly V-belt to crankshaft pulley/vibration damper and cool‐

itte

y li
rm

ant pump pulley.

ab
pe

ility
ot

wit
, is n

– Lift tensioning roller with poly V-belt lever -3299- and fit poly
h re

V-belt onto alternator belt pulley.

hole

spec
es, in part or in w

– Lower tensioning roller onto poly V-belt with poly V-belt lever
t to the co

-3299- .
– Installing V-belt for power assisted steering vane pump ⇒
rrectness of i

Running gear, axles, steering from January 1996; Rep. Gr.

48 ; Repairing power assisted steering .
l purpos

– Start engine and check belt running.

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
78
cted agen
Prote AG.
Rep. Gr.27 - Starter, current supply, CCS
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

10.5.4 Poly V-belt drives

Alternator, second alternator and power assisted steering vane
pump (4-cylinder petrol and diesel engine)
1 - Belt pulley - alternator
2 - Idler roller
3 - Belt pulley - second alternator
4 - Belt pulley - power assisted steering vane pump
5 - Belt pulley - crankshaft
6 - Idler roller
7 - Tensioning roller
8 - Poly V-belt

Alternator, power assisted steering vane pump and air conditioner

compressor (4-cylinder petrol and diesel engine)
1 - Belt pulley - alternator
2 - Idler roller wage
n AG. Volkswagen AG do
es n
lks ot g
Vo
3 - Belt pulley - air conditioner compressor d by ua
ran
ir se tee
o
4 - Belt pulley - power assisted steering vane au pump
th or
ac
ss
5 - Belt pulley - crankshaft

ce
e
nl

pt
du

an
6 - Idler roller
itte

y li
erm

ab
7 - Tensioning roller

ility
ot p

wit
, is n

8 - Poly V-belt

h re
hole

spec
10.6 4-cylinder engine with air conditioner
es, in part or in w

t to the co
compressor or 2nd alternator 05.99 ▸

rrectness of i
10.6.1 Assembly overview
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

10. Alternator with poly V-belt 79

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1 - Hexagon bolt M8×48

❑ 25 Nm
2 - Bush 30 x 18 x 10
3 - Hexagon collared bolts
M8×25
❑ 25 Nm
4 - Bracket
5 - Bracket for alternator and
air conditioner compressor or
2nd alternator
6 - Self-locking hexagon nut
M8
❑ 33 Nm
❑ Always renew.
7 - Cross-head screws
8 - Hexagon nut
❑ M8
9 - Hexagon nut
❑ M8
AG. Volkswagen AG d
agen oes
10 - Cross-head screw olksw not
byV gu
ara
ed
11 - Voltage regulator horis nte
eo
ut ra
❑ Removing and installing ss a c
⇒ page 105 .

ce
e
nl

pt
du

❑ Checking carbon brush‐

an
itte

y li
es ⇒ page 106 .
erm

ab
ility
ot p

12 - Protective cap
wit
, is n

13 - Alternator h re
hole

spec
14 - Poly V-belt
es, in part or in w

t to the co

❑ Removing and installing

⇒ page 80 and ⇒ page 82
❑ Poly V-belt drives ⇒ page 85 and ⇒ page 85
rrectness of i

15 - Hexagon bolt M8×92

l purpos

❑ 25 Nm
nform
ercia

16 - Stud bolts with hexagon M8×55 / M8×51

m

❑ 25 Nm
at
om

ion
c

Remain fitted when removing

in t
or

his
ate

do
priv

10.6.2 Removing and installing poly V-belt, 4-

um
for

en
ng

t.
cylinder petrol engine
yi Co
Cop py
ht. rig
rig ht
– Remove noise insulation tray ⇒ General body repairs, exteri‐ py by
co Vo
or; Rep. Gr. 50 ; Body front; Assembly overview - noise
by lksw
cted agen
Prote
insulation .
AG.

80 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Vehicles with belt tension damper

Removing:

Note

Before removing, mark the top side and direction of rotation of the
poly V-belt. When installing, ensure correct fitting position and
direction of rotation. If the belt is installedaginnthe wrong
AG. Volkswagposition
en AG
doeor
w e
against direction of rotation, the belty Vo will be destroyed!
lks s no
tg
b ua
ed ran
oris tee
– Clamp commercially available
au
th assembly lever between retain‐ or
ac
ing lugs -1- and slowly
ss pull in direction of arrow until belt
tension damper is so relaxed that poly V-belt can be removed

ce
e
nl

pt
du

from tensioning roller.

an
itte

y li
erm

ab
– Loosen top belt tension damper and remove poly V-belt.

ility
ot p

Installing:

wit
, is n

h re
hole

spec
es, in part or in w

Note

t to the co
♦ When fitting used poly V-belts observe the direction of rotation
marked on removal!

rrectness of i
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
l purpos

leys!

nform
ercia

– Fit poly V-belt to crankshaft pulley/vibration damper and if

necessary coolant pump pulley / 2nd alternator-belt pulley.
m

at
om

ion
c

in t
– Install poly V-belt and firmly screw on top belt tension damper.
or

his
ate

do
riv

– Raise tensioning roller with assembly lever and place poly V-

p

cum

belt on alternator pulley.

for

en
ng

t.
yi
– Lower tensioning roller with assembly lever on poly V-belt.
Co
Cop py
t. rig
gh
– Start engine and check belt running.
ht
pyri by
Vo
co lksw
by
cted
Vehicles with tensioning element
agen
Prote AG.

Special tools and workshop equipment required

♦ Poly V-belt lever -3299-

10. Alternator with poly V-belt 81

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Removing:

Note

Before removing, mark the top side and direction of rotation of the
poly V-belt. When installing, ensure correct fitting position and
direction of rotation. If the belt is installed in the wrong position or
against direction of rotation, the belt will be destroyed!

– Lift tensioning roller with poly V-belt lever -3299- and remove
poly V-belt from alternator belt pulley.
– Remove poly V-belt.
Installing:

Note

♦ When fitting used poly V-belts observe the direction of rotation

marked on removal!
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
leys!
AG. Volkswagen AG d
agen oes
ksw
– Fit poly V-belt to crankshaft pulley/vibration by V damper and if
ol not
gu
ara
necessary coolant pump pulley / 2nd ris alternator-belt pulley.
ed
nte
ho eo
aut ra
s c
– Lift tensioning roller with poly V-belt
s lever -3299- and fit poly

ce
le

V-belt onto alternator belt pulley.

un

pt
an
d
itte

y li
– Lower tensioning roller onto poly V-belt with poly V-belt lever
erm

ab
-3299- .
ility
ot p

wit
– Start engine and check belt running.
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness

10.6.3 Removing and installing poly V-belt, 4-

o
cial p

f in

cylinder diesel engine

form
mer

atio

Belt drive without tensioning roller

om

n
c

i
or

Special tools and workshop equipment required

thi
te

sd
va

♦ Tensioning lever -3297-

i

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

82 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Removing:

Note

Before removing, mark the top side and direction of rotation of the
poly V-belt. When installing, ensure correct fitting position and
direction of rotation. If the belt is installed in the wrong position or
against direction of rotation, the belt will be destroyed!

– Unscrew alternator securing bolts -1- and -2- at least one turn.
– Lower alternator with tensioning lever -3297- and remove poly
V-belt from alternator pulley.
– Removing V-belt for power assisted steering vane pump ⇒
Running gear, axles, steering from January 1996; Rep. Gr.
48 ; Repairing power assisted steering .
Installing:

Note

♦ When fitting used poly V-belts observe the direction of rotation

marked on removal!
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
Volkswa
leys! ksw
agen
AG. gen AG
does
ol not
yV gu
db ara
– Fit poly V-belt to crankshaft pulley, vibration
rise damper and cool‐ nte
tho eo
ant pump pulley. s au ra
c
s
– Installing V-belt for power assisted steering vane pump ⇒

ce
e
nl

pt
du

Running gear, axles, steering from January 1996; Rep. Gr.

an
itte

y li
48 ; Repairing power assisted steering .
erm

ab
ility
ot p

– Lower alternator with tensioning lever -3297- and place poly

wit
V-belt on alternator pulley.
, is n

h re
hole

spec
– Push alternator down at least 3 times onto stop with tensioning
es, in part or in w

lever -3297- to ensure the alternator moves freely.

t to the co
– With alternator still detached, allow engine to run at idling
speed for at least 10 seconds.
rrectness of i

– Switch off engine and tighten alternator securing bolts.

l purpos

– Tighten threaded connections to specified torque settings

⇒ page 120 .
nform
ercia

1. Securing bolt -2-

m

at
om

io

2. Securing bolt -1-

n
c

in t
or

his
ate

do
priv

Note
um
for

en
ng

t.
yi Co
When tightening keep to the following sequence, do not use the Cop py
t. rig
alternator for support and do not touch poly V-belt. opyri
gh by
Vo
ht
by c lksw
cted agen
Belt drive with automatic tensioning roller
Prote AG.

Special tools and workshop equipment required

10. Alternator with poly V-belt 83

 AG. Volkswagen AG d
agen oes
olksw not
y V gu
Transporter 1991 ➤ , Transporter
rise
d b
1996 ➤ ara
nte
Electrical system - Edition
aut 10.2004
ho eo
ra
ss c

ce
le
♦ Poly V-belt lever -3299-

un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f i
Removing:

nform
mer

atio
om

n
Note
c

i
or

n thi
te

sd
a

Before removing, mark the top side and direction of rotation of the
iv

o
pr

c
poly V-belt. When installing, ensure correct fitting position and

um
r
fo

en
ng

direction of rotation. If the belt is installed in the wrong position or

t.
yi Co
against direction of rotation, the belt will be destroyed! Cop py
t. rig
gh ht
pyri by
Vo
o
– Lift tensioning roller with poly V-belt lever -3299- and remove
c by lksw
cted agen
poly V-belt from alternator belt pulley. Prote AG.

– Removing V-belt for power assisted steering vane pump ⇒

Running gear, axles, steering from January 1996; Rep. Gr.
48 ; Repairing power assisted steering .
– Remove poly V-belt.
Installing:

Note

♦ When fitting used poly V-belts observe the direction of rotation

marked on removal!
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
leys!

– Fit poly V-belt to crankshaft pulley/vibration damper and cool‐

ant pump pulley.

– Lift tensioning roller with poly V-belt lever -3299- and fit poly
V-belt onto alternator belt pulley.
– Lower tensioning roller onto poly V-belt with poly V-belt lever
-3299- .
– Installing V-belt for power assisted steering vane pump ⇒
Running gear, axles, steering from January 1996; Rep. Gr.
48 ; Repairing power assisted steering .
– Start engine and check belt running.

84 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

10.6.4 Poly V-belt drives

Alternator, second alternator and power assisted steering vane
pump (4-cylinder petrol and diesel engine)
1 - Belt pulley - alternator
2 - Idler roller
3 - Belt pulley - second alternator
4 - Belt pulley - power assisted steering vane pump
5 - Belt pulley - crankshaft
6 - Idler roller
7 - Tensioning roller
8 - Poly V-belt

Alternator, power assisted steering vane pump and air conditioner

compressor (4-cylinder petrol and diesel engine)
1 - Belt pulley - alternator
2 - Idler roller
3 - Belt pulley - air conditioner compressor
4 - Belt pulley - power assisted steering vane pump
5 - Belt pulley - crankshaft
6 - Idler roller
7 - Tensioning roller
AG. Volkswagen AG d
agen
8 - Poly V-belt Volksw
oes
not
gu
d by ara
ise nte
r
10.7 5-cylinder engine without air conditioner ho eo
aut ra
s c
or 2nd alternator ▸ 04.99
s
ce
e
nl

pt
du

an
itte

y li
erm

ab

10.7.1 Assembly overview

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

10. Alternator with poly V-belt 85

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1 - Hexagon bolts M8×85

❑ 40 Nm
2 - Hexagon socket head bolt
❑ 40 Nm
❑ With washer
3 - Bracket
4 - Hexagon bolts M8×50
❑ 40 Nm
5 - Alternator
6 - Voltage regulator
❑ Removing and installing
⇒ page 103 .
❑ Checking carbon brush‐
es ⇒ page 104 .
7 - Fillister head bolts with
cross head M4×25 AG. Volkswagen AG d
agen oes
olksw not
yV gu
8- Protective cap ed b ara
nte
ris
ho eo
9- Hexagon boltsauM3
t ra
c
ss
10 - Poly V-belt
ce
e
nl

pt
du

an

❑ Removing and installing

itte

y li

⇒ page 86 .
erm

ab
ility
ot p

❑ Poly V-belt drives

wit
, is n

⇒ page 87 and
h re

⇒ page 88
hole

spec
es, in part or in w

11 - Tensioning roller
t to the co
rrectness of i
l purpos

nform
ercia

10.7.2 Removing and installing poly V-belt

m

at
om

io

Special tools and workshop equipment required

n
c

in t
or

♦ Poly V-belt lever -3299-

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

(Only for vehicles with tensioning roller)

86 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Removing:

Note

Before removing, mark the top side and direction of rotation of the
poly V-belt. When installing, ensure correct fitting position and
direction of rotation. If the belt is installed in the wrong position or
against direction of rotation, the belt will be destroyed!

– Remove noise insulation tray ⇒ General body repairs, exteri‐

or; Rep. Gr. 50 ; Body front; Assembly overview - noise
insulation . AG. Volkswagen gen AG do
swa es n
– Lift tensioning roller with poly V-belt leverby-3299-
Vol
k and remove ot g
ua
poly V-belt from alternator belt pulley.rised ran
tee
tho or
– Remove poly V-belt. s au ac
s

ce
e

Installing:
nl

pt
du

an
itte

y li
erm

ab
Note

ility
ot p

wit
, is n

h re
♦ When fitting used poly V-belts observe the direction of rotation
hole

spec
marked on removal!
es, in part or in w

t to the co
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
leys!
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐

rrectness of i
nator, air conditioner compressor, power assisted steering
vane pump) are secured tightly.
l purpos

– Fit poly V-belt to crankshaft pulley/vibration damper and if

nf
ercia

o
necessary coolant pump pulley / 2nd alternator-belt pulley.

rm
m

atio
om

n in
– Lift tensioning roller with poly V-belt lever -3299- and fit poly
or c

V-belt onto alternator belt pulley.

thi
te

sd
iva

o
r

– Lower tensioning roller onto poly V-belt with poly V-belt lever
rp

cu
o

-3299- .
f

en
ng

t.
yi Co
op
– Start engine and check belt running. C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

10.7.3 Poly V-belt drives

Alternator and power assisted steering vane pump (5-cylinder
petrol and diesel engine)
1 - Belt pulley - alternator
2 - Poly V-belt
3 - Belt pulley - power assisted steering vane pump
4 - Belt pulley - crankshaft
5 - Tensioning roller

10. Alternator with poly V-belt 87

 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Transporter 1991 ➤uth, Transporter 1996 ➤
o eo
ra
a
Electrical systems - Edition 10.2004
s c

ce
e
nl

pt
du
Alternator and power assisted steering vane pump (5-cylinder TDI

an
itte

y li
engine)

erm

ab
ility
ot p
1 - Belt pulley - alternator

wit
, is n

h re
2 - Poly V-belt
hole

spec
3 - Belt pulley - power assisted steering vane pump
es, in part or in w

t to the co
4 - Belt pulley - crankshaft
5 - Idler roller

rrectness of i
6 - Tensioning roller
l purpos

nform
ercia

10.8 5-cylinder engine without air conditioner

m

at
or 2nd alternator 05.99 ▸
om

ion
c

in t
or

his
ate

do
riv

10.8.1 Assembly overview

p

cum
for

en
ng

t.
yi Co
Cop py
1 - Hexagon bolts M8×85 ht. rig
rig ht
py by
❑ 40 Nm co Vo
by lksw
cted agen
Prote AG.
2 - Hexagon socket head bolt
❑ 40 Nm
❑ With washer
3 - Bracket
4 - Hexagon bolts M8×50
❑ 40 Nm
5 - Alternator
6 - Cross-head screws
7 - Hexagon nut
❑ M8
8 - Hexagon nut
❑ M8
9 - Cross-head screw
10 - Voltage regulator
❑ Removing and installing
⇒ page 105 .
❑ Checking carbon brush‐
es ⇒ page 106 .
11 - Protective cap
12 - Poly V-belt
❑ Removing and installing
⇒ page 88 .
❑ Poly V-belt drives
⇒ page 90 and
⇒ page 90
13 - Tensioning roller

10.8.2 Removing and installing poly V-belt

Special tools and workshop equipment required

88 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

♦ Poly V-belt lever -3299-

(Only for vehicles with tensioning roller)

Removing:

Note

Before removing, mark the top side and direction of rotation of the
poly V-belt. When installing, ensure correct fitting position and
direction of rotation. If the belt is installed in the wrong position or
against direction of rotation, the belt will be destroyed!

– Remove noise insulation tray ⇒ General body repairs, exteri‐

olkswagen AG
or; Rep. Gr. 50 ; Body front;
wa en AG. V
gAssembly overview do-enoise
s no
ks
insulation . by
Vol t gu
d ara
se n
– Lift tensioning roller
ho
ri with poly V-belt lever -3299- and remove
tee
ut or
poly V-belt from
ss
a alternator belt pulley. ac
ce
e

– Remove poly V-belt.

nl

pt
du

an
itte

y li

Installing:
erm

ab
ility
ot p

wit
, is n

Note
h re
hole

spec

♦ When fitting used poly V-belts observe the direction of rotation

es, in part or in w

t to the co

marked on removal!
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
leys!
rrectness of i

♦ Before installing poly V-belt, ensure that all ancillaries (alter‐

l purpos

nator, air conditioner compressor, power assisted steering

vane pump) are secured tightly.
nf
ercia

orm

– Fit poly V-belt to crankshaft pulley/vibration damper and if

m

atio
m

necessary coolant pump pulley / 2nd alternator-belt pulley.

o

n in
or c

thi
te

sd

– Lift tensioning roller with poly V-belt lever -3299- and fit poly
iva

o
r

V-belt onto alternator belt pulley.

rp

cu
o

m
f

en
ng

– Lower tensioning roller onto poly V-belt with poly V-belt lever
t.
yi Co
op
-3299- .
C py
ht. rig
rig ht
py by
– Start engine and check belt running. co Vo
by lksw
cted agen
Prote AG.

10. Alternator with poly V-belt 89

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

10.8.3 Poly V-belt drives

Alternator and power assisted steering vane pump (5-cylinder gen AG. Volkswagen AG d
a
petrol and diesel engine) Vol
ksw
oes
not
g by ua
ed ran
1 - Belt pulley - alternator oris tee
th or
au
2 - Poly V-belt ss
ac

ce
e
nl
3 - Belt pulley - power assisted steering vane pump

pt
du

an
itte

y li
4 - Belt pulley - crankshaft

erm

ab
ility
ot p
5 - Tensioning roller

wit
, is n

h re
hole

spec
Alternator and power assisted steering vane pump (5-cylinder TDI
es, in part or in w

t to the co
engine)
1 - Belt pulley - alternator

rrectness of i
2 - Poly V-belt
l purpos

3 - Belt pulley - power assisted steering vane pump

4 - Belt pulley - crankshaft

nf
ercia

or
5 - Idler roller

m
m

atio
m

6 - Tensioning roller
o

n in
or c

thi
te

sd
iva

o
r
rp

cu
10.9 5-cylinder engines with air conditioner or
o

m
f

en
ng

t.
yi
2nd alternator or hydraulic pump ▸
Co
Cop py
t. rig
04.99
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

10.9.1 Assembly overview

90 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004
olkswagen AG
en AG. V
1 - Poly V-belt ksw
ag does
not
y Vol gu
❑ Removing and installing ed
b ara
nte
ris
⇒ page 91 . tho eo
au ra
❑ Poly V-belt drives ss c
⇒ page 93 ,

ce
e
nl

pt
du
⇒ page 93 and

an
itte

y li
⇒ page 93

erm

ab
ility
2 - Alternator ot p

wit
, is n

h re
3 - Voltage regulator
hole

spec
❑ Removing and installing
es, in part or in w

⇒ page 103 .

t to the co
❑ Checking carbon brush‐
es ⇒ page 104 .

rrectness of i
4 - Fillister head bolts with
l purpos

cross head M4×25

5 - Protective cap

nform
ercia

6 - Hexagon bolts M3
m

at
om

7 - Hexagon bolt M8×45

ion
c

in t
r

❑ 40 Nm
o

his
ate

do
riv

8 - Bracket
p

cum
for

en
g

9 - Hexagon bolts M10×120

n

t.
yi Co
op
❑ 40 Nm
C py
t. rig
gh ht
yri
❑ With washer p by
o Vo
by c lksw
cted agen
10 - Hexagon bolts M10×45 Prote AG.

❑ 40 Nm
❑ With washer
11 - Allen head bolt M8×35
❑ 20 Nm
12 - Hexagon bolts M8×85
❑ 25 Nm
13 - Bolt and washer assembly M10×38
❑ 40 Nm

10.9.2 Removing and installing poly V-belt

Special tools and workshop equipment required
♦ Poly V-belt lever -3299-

(Only for vehicles with tensioning roller)

10. Alternator with poly V-belt 91

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004
AG. Volkswagen AG d
agen oes
Removing: olksw not
y V gu
d b ara
rise nte
tho eo
u ra
Note ss a c

ce
le
un

pt
Before removing, mark the top side and direction of rotation of the

an
d
itte

y li
poly V-belt. When installing, ensure correct fitting position and

erm

ab
direction of rotation. If the belt is installed in the wrong position or

ility
ot p
against direction of rotation, the belt will be destroyed!

wit
is n

h re
ole,

spec
– Remove noise insulation tray ⇒ General body repairs, exteri‐

urposes, in part or in wh
or; Rep. Gr. 50 ; Body front; Assembly overview - noise

t to the co
insulation .
– Lift tensioning roller with poly V-belt lever -3299- and remove

rrectne
poly V-belt from alternator belt pulley.
– Remove poly V-belt.

ss o
Installing:
cial p

f inform
mer

atio
Note
om

n
c

i
or

n thi
♦ When fitting used poly V-belts observe the direction of rotation
te

sd
va

marked on removal!
i

o
pr

cum
r
fo

♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐

en
ng

t.
yi Co
leys! t. Cop py
rig
gh ht
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐ pyri by
Vo
o
nator, air conditioner compressor, power assisted steering
c by lksw
cted agen
vane pump) are secured tightly.
Prote AG.

– Fit poly V-belt to crankshaft pulley/vibration damper and if

necessary coolant pump pulley / 2nd alternator-belt pulley.

– Lift tensioning roller with poly V-belt lever -3299- and fit poly
V-belt onto alternator belt pulley.
– Lower tensioning roller onto poly V-belt with poly V-belt lever
-3299- .
– Start engine and check belt running.

92 Rep. Gr.27 - Starter, current supply, CCS

 AG. Volkswagen AG d
agen oes
olksw not
yV gu
Transporter
ised b 1991 ➤ , Transporter 1996 ara➤
nte
r
ut
ho Electrical system - Edition 10.2004 e or
a ac
ss

ce
10.9.3 Poly V-belt drives

le
un

pt
an
d
itte

y li
Alternator, power assisted steering vane pump and air conditioner

erm

ab
compressor (5-cylinder petrol and diesel engine)

ility
ot p

wit
is n
1 - Belt pulley - alternator

h re
ole,

spec
2 - Idler roller

urposes, in part or in wh

t to the co
3 - Belt pulley - air conditioner compressor
4 - Belt pulley - power assisted steering vane pump

rrectne
5 - Belt pulley - crankshaft
6 - Idler roller

ss o
cial p

f
7 - Tensioning roller

inform
mer
8 - Poly V-belt

atio
om

n
c

i
Alternator, hydraulic pump and power assisted steering vane
or

n thi
e
pump (5-cylinder petrol and diesel engine)
t

sd
iva

o
pr

c
1 - Belt pulley - alternator

um
r
fo

en
ng
t.
yi
2 - Idler roller
Co
Cop py
t. rig
gh
3 - Belt pulley - hydraulic pump
ht
pyri by
Vo
o
by c lksw
cted
4 - Belt pulley - power assisted steering vane pump
agen
Prote AG.

5 - Belt pulley - crankshaft

6 - Idler roller
7 - Tensioning roller
8 - Poly V-belt

Alternator, second alternator and power assisted steering vane

pump (5-cylinder petrol and diesel engine)
1 - Belt pulley - alternator
2 - Idler roller
3 - Belt pulley - second alternator
4 - Belt pulley - power assisted steering vane pump
5 - Belt pulley - crankshaft
6 - Idler roller
7 - Tensioning roller
8 - Poly V-belt

10.10 5-cylinder engines with air conditioner or

2nd alternator or hydraulic pump 05.99
▸

10.10.1 Assembly overview

10. Alternator with poly V-belt 93

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1 - Cross-head screws
2 - Hexagon nut
❑ M8
3 - Hexagon nut
❑ M8
4 - Cross-head screw
5 - Voltage regulator
❑ Removing and installing
⇒ page 105 .
❑ Checking carbon brush‐
es ⇒ page 106 .
6 - Protective cap
7 - Alternator
8 - Poly V-belt
❑ Removing and installing
⇒ page 94 .
❑ Poly V-belt drives
⇒ page 96 ,
⇒ page 96 and
⇒ page 96
9 - Hexagon bolt M8×45
❑ 40 Nm
10 - Bracket
11 - Hexagon bolts M10×120
❑ 40 Nm
❑ With washer
12 - Hexagon bolts M10×45
❑ 40 Nm AG. Volkswagen AG d
agen oes
olksw not
❑ With washer d by V gu
ara
rise nte
13 - Allen head bolt M8×35 autho eo
ra
s c
❑ 20 Nm s
ce
le
un

pt

14 - Hexagon bolt M8×85

an
d
itte

y li

❑ 25 Nm
erm

ab
ility
ot p

15 - Bolt and washer assembly M10×38

wit
is n

h re

❑ 40 Nm
ole,

spec
urposes, in part or in wh

16 - Hexagon bolt M8×85

t to the co

❑ 25 Nm
rrectne

10.10.2 Removing and installing poly V-belt

ss

Special tools and workshop equipment required

o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
94
Prote AG.
Rep. Gr.27 - Starter, current supply, CCS
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

♦ Poly V-belt lever -3299- agen

AG. Volkswagen AG d
oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
(Only for vehicles with tensioning roller)

rrectness of i
Removing:
l purpos

Note

nform
ercia

Before removing, mark the top side and direction of rotation of the
m

a
com

ti
poly V-belt. When installing, ensure correct fitting position and

on in
direction of rotation. If the belt is installed in the wrong position or
r
te o

thi
against direction of rotation, the belt will be destroyed!

s
iva

do
r
rp

cum
fo

– Remove noise insulation tray ⇒ General body repairs, exteri‐

en
ng

t.
yi
or; Rep. Gr. 50 ; Body front; Assembly overview - noise
Co
Cop py
insulation . ht. rig
rig ht
py by
o Vo
– Lift tensioning roller with poly V-belt lever -3299- and remove by c lksw
cted agen
poly V-belt from alternator belt pulley. Prote AG.

– Remove poly V-belt.

Installing:

Note

♦ When fitting used poly V-belts observe the direction of rotation

marked on removal!
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
leys!
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐
nator, air conditioner compressor, power assisted steering
vane pump) are secured tightly.

– Fit poly V-belt to crankshaft pulley/vibration damper and if

necessary coolant pump pulley / 2nd alternator-belt pulley.

– Lift tensioning roller with poly V-belt lever -3299- and fit poly
V-belt onto alternator belt pulley.
– Lower tensioning roller onto poly V-belt with poly V-belt lever
-3299- .
– Start engine and check belt running.

10. Alternator with poly V-belt 95

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

10.10.3 Poly V-belt drives

Alternator, power assisted steering vane pump and air conditioner
compressor (5-cylinder petrol and diesel engine)
1 - Belt pulley - alternator
2 - Idler roller
3 - Belt pulley - air conditioner compressor
4 - Belt pulley - power assisted steering vane pump
5 - Belt pulley - crankshaft
6 - Idler roller
7 - Tensioning roller
8 - Poly V-belt

Alternator, hydraulic pump and power assisted steering vane

pump (5-cylinder petrol and diesel engine)
1 - Belt pulley - alternator
2 - Idler roller
3 - Belt pulley - hydraulic pump
4 - Belt pulley - power assisted steering vane pump
5 - Belt pulley - crankshaft
6 - Idler roller
7 - Tensioning roller
8 - Poly V-belt

Alternator, second alternator and power assisted steering vane

pump (5-cylinder petrol and diesel engine) wagen AG. Volkswagen AG doe
ks s no
Vol t gu
1 - Belt pulley - alternator ed by ara
ris nte
2 - Idler roller utho eo
ra
a c
ss
3 - Belt pulley - second alternator
ce
le
un

pt
an
d

4 - Belt pulley - power assisted steering vane pump

itte

y li
rm

ab

5 - Belt pulley - crankshaft

pe

ility
ot

wit
, is n

6 - Idler roller
h re
hole

spec

7 - Tensioning roller
es, in part or in w

t to the co

8 - Poly V-belt

10.11 6-cylinder fuel injection engine ▸ 04.99

rrectness of i
l purpos

10.11.1 Assembly overview

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

96 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1 - Hexagon bolt M8
❑ 25 Nm
2 - Bracket
3 - Hexagon socket bolt and
washer assemblies M8×60
❑ 25 Nm
4 - Washer
5 - Fitted bolt M8×60
❑ 25 Nm
6 - Hexagon bolt M8
❑ 25 Nm
7 - Poly V-belt
❑ Removing and installing
⇒ page 97 .
❑ Poly V-belt drives
⇒ page 99 and
⇒ page 99
8 - Alternator
9 - Voltage regulator
❑ Removing and installing
⇒ page 103 .
❑ Checking carbon brush‐
es ⇒ page 104 .
10 - Fillister head bolts with wage
n AG. Volkswagen AG do
es n
s
cross head M4×25 yV
olk ot g
ua
d b ran
11 - Protective cap ir se tee
tho
u or
a ac
12 - Hexagon bolts M3 ss

ce
e
nl

pt
13 - Bracket between alterna‐
du

an
itte

tor and air conditioner com‐

y li
erm

ab
pressor

ility
ot p

wit
14 - Fitted bolt M8×60
, is n

h re
❑ 25 Nm
hole

spec
es, in part or in w

15 - Washer

t to the co
16 - Hexagon socket bolt and washer assembly M8×60
❑ 25 Nm rrectness of i
17 - Hexagon socket bolt and washer assembly M8×20
l purpos

❑ 25 Nm
nform
mercia

at

10.11.2 Removing and installing poly V-belt

om

ion
c

in t
or

Special tools and workshop equipment required

his
ate

do
riv

♦ Hexagon bolt M8×30

p

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

10. Alternator with poly V-belt 97

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Removing:

Note

Before removing, mark the top side nand direction

AG. Volkswagenof
AGrotation of the
poly V-belt. When installing, lkswage correct fitting position
ensure
does
not and
Vo
direction of rotation. If sthe
d b belt is installed in the wrong position
y gu
araor
i e
against direction of throtation,
or the belt will be destroyed! nte
eo
au ra
c
ss
– Remove noise insulation tray ⇒ General body repairs, exteri‐

ce
le
un

pt
or; Rep. Gr. 50 ; Body front; Assembly overview - noise

an
d
itte

insulation .

y li
erm

ab
ility
– Screw bolt M8×80 in threaded hole -A- of tensioning roller until
ot p

wit
poly V-bolt is relaxed.
is n

h re
ole,

spec
urposes, in part or in wh

Note

t to the co
Screw in bolt only until poly V-belt can be removed, otherwise
tensioning roller housing may become damaged.

rrectne
– Remove poly V-belt.

ss o
cial p

f
Installing:

inform
mer

atio
m

Note
o

n
c

i
or

n thi
te

♦ When fitting used poly V-belts observe the direction of rotation

sd
iva

o
r

marked on removal!
p

cum
r
fo

en
ng

♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
t.
yi Co
op
leys! C py
t. rig
gh ht
yri by
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐ cop Vo
by lksw
nator, air conditioner compressor, power assisted steering cted agen
Prote AG.
vane pump) are secured tightly.

– Fit poly V-belt.

– Remove M8 bolt from tensioning roller again.
– Start engine and check belt routing.

Note

Engines with air conditioner compressor are fitted with a double

poly V-belt.

98 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

10.11.3 Poly V-belt drives

Alternator and power steering vane pump (6-cylinder injection
engine)
1 - Belt pulley - alternator
n AG. Volkswagen AG do
wage es n
2 - Poly V-belt yV
olks ot g
ua
b
ed ran
3 - Belt pulley - power assisted steering vane pumphoris tee
ut or
a ac
4 - Belt pulley - crankshaft ss

ce
le
un

pt
5 - Belt pulley - coolant pump

an
d
itte

y li
6 - Tensioning roller
rm

ab
pe

ility
ot

wit
, is n

Alternator, power assisted steering vane pump and air conditioner

h re
compressor (6-cylinder injection engine)
hole

spec
es, in part or in w

1 - Belt pulley - alternator

t to the co
2 - Poly V-belt
3 - Belt pulley - air conditioner compressor

rrectness of i
4 - Belt pulley - power assisted steering vane pump
l purpos

5 - Belt pulley - crankshaft

nform
ercia

6 - Belt pulley - coolant pump

m

a
7 - Tensioning roller
com

tion in
r
te o

thi
10.12 6-cylinder fuel injection engine 05.99 ▸

s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
10.12.1 Assembly overview Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

10. Alternator with poly V-belt 99

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1 - Hexagon bolt M8
❑ 25 Nm
2 - Bracket
3 - Hexagon socket bolt and
washer assemblies M8×60
❑ 25 Nm
4 - Washer
5 - Fitted bolt M8×60
❑ 25 Nm
6 - Hexagon bolt M8
❑ 25 Nm
7 - Poly V-belt
❑ Removing and installing
⇒ page 100 .
❑ Poly V-belt drives
⇒ page 102 and
⇒ page 102
8 - Alternator
9 - Protective cap
10 - Voltage regulator
❑ Removing and installing n AG. Volkswagen AG do
⇒ page 105 . olkswage es n
ot g
yV
❑ Checking carbon brush‐ d b ua
ran
ir se
es ⇒ page 106 . tho tee
or
au ac
11 - Cross-head screws ss

ce
le
un

pt
12 - Hexagon nut

an
d
itte

y li
❑ M8
erm

ab
ility
ot p

13 - Cross-head screw

wit
is n

h re
14 - Hexagon nut
ole,

spec
urposes, in part or in wh

❑ M8

t to the co
15 - Bracket between alternator and air conditioner compressor
16 - Fitted bolt M8×60 rrectne
❑ 25 Nm
s

17 - Washer
s o
cial p

18 - Hexagon socket bolt and washer assembly M8×60

inform
mer

❑ 25 Nm
atio
m

19 - Hexagon socket bolt and washer assembly M8×20

o

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r

10.12.2 Removing and installing poly V-belt

fo

en
ng

t.
yi Co
op
Special tools and workshop equipment required
C py
t. rig
gh ht
yri by
♦ Hexagon bolt M8×30 cop Vo
by lksw
cted agen
Prote AG.

100 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
en AG. V Electrical
olkswagen AGsystem - Edition 10.2004
ag does
ksw not
y Vol gu
Removing: ed
b ara
nte
oris eo
th
au ra
c
ss
Note

ce
le
un

pt
an
d
itte
Before removing, mark the top side and direction of rotation of the

y li
erm

ab
poly V-belt. When installing, ensure correct fitting position and

ility
ot p
direction of rotation. If the belt is installed in the wrong position or

wit
is n
against direction of rotation, the belt will be destroyed!

h re
ole,

spec
urposes, in part or in wh
– Remove noise insulation tray ⇒ General body repairs, exteri‐

t to the co
or; Rep. Gr. 50 ; Body front; Assembly overview - noise
insulation .
– Screw bolt M8×80 in threaded hole -A- of tensioning roller until

rrectne
poly V-bolt is relaxed.

ss o
cial p

f
Note

inform
mer

Screw in bolt only until poly V-belt can be removed, otherwise

atio
m

tensioning roller housing may become damaged.

o

n
c

i
or

n thi
te

sd
a

– Remove poly V-belt.

iv

o
pr

cum
r
fo

Installing:

en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri
Note
p by
co Vo
by lksw
cted agen
Prote AG.
♦ When fitting used poly V-belts observe the direction of rotation
marked on removal!
♦ When fitting belt, ensure that poly V-belt seats correctly in pul‐
leys!
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐
nator, air conditioner compressor, power assisted steering
vane pump) are secured tightly.

– Fit poly V-belt.

– Remove M8 bolt from tensioning roller again.
– Start engine and check belt running.

Note

Engines with air conditioner compressor are fitted with a double

poly V-belt.

10. Alternator with poly V-belt 101

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

10.12.3 Poly V-belt drives

Alternator and power assisted steering vane pump (6-cylinder in‐
jection engine)
1 - Belt pulley - alternator
2 - Poly V-belt
3 - Belt pulley - power assisted steering vane pump
4 - Belt pulley - crankshaft
5 - Belt pulley - coolant pump
6 - Tensioning roller

Alternator, power assisted steering vane pump and air conditioner

compressor (6-cylinder injection engine)
1 - Belt pulley - alternator
2 - Poly V-belt
3 - Belt pulley - air conditioner compressor
agen
AG. Volkswagen AG d
o w es n
olks ot g
4 - Belt pulley - power
ed
byassisted steering vane pump
V ua
ran
ris tee
5 - Belt pulley a-utcrankshaft
ho or
ac
ss
6 - Belt pulley - coolant pump
ce
e
nl

pt
du

an

7 - Tensioning roller
itte

y li
erm

ab
ility
ot p

10.13 Compact alternator with poly V-belt

wit
, is n

drive ▸ 04.99
h re
hole

spec
es, in part or in w

t to the co

10.13.1 Securing B+ (battery positive) wire to al‐

ternator
rrectness of i

Special tools and workshop equipment required

l purpos

♦ Torque wrench -V.A.G 1331-

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Different alternators with different securing variants for D+ wire

are installed.
– The torque setting for the securing nut of the B+ wire -arrow-
can be gleaned from the “Torque settings” table
⇒ page 120 .

102 Rep. Gr.27 - Starter, current supply, CCS

 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
uth oTransporter
ra 1991 ➤ , Transporter 1996 ➤
a c
ss Electrical system - Edition 10.2004

ce
le
un

pt
an
d
itte

y li
rm

ab
Note
pe

ility
ot

wit
, is n

♦ If the B+ wire or the D+ wire is not secured to prescribed torque

h re
hole

setting, the following may occur:

spec
es, in part or in w

♦ The battery will not be charged fully.

t to the co
♦ Vehicle electrics or electronics fail completely (breakdown).

rrectness of i
♦ Danger of fires from sparks.
♦ Damage to electronic components and control units due to
l purpos

excessive voltage.

nform
ercia

Alternators with push-on connector for D+ wire

m

a
com

t
– Tighten threaded connections to specified torque settings

ion in
⇒ page 120 .
r
te o

thi
s
iva

Alternators with screwed connection for D+ wire

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Tighten threaded connections to specified torque settings

⇒ page 120 .

10.13.2 Removing and installing voltage regula‐

tor for alternator ▸ 04.99
– Unscrew protective cap securing bolts -arrows- and remove
protective cap.
– Remove voltage regulator securing bolts and remove voltage
regulator.
Install in the reverse order of removal. When doing this, note the
following:
– Tighten threaded connections to specified torque settings
⇒ page 120 .

10. Alternator with poly V-belt 103

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

10.13.3 Checking alternator carbon brushes ▸

04.99
Length of new carbon brushes = 12 mm
Wear limit = 5 mm
Carbon brush tolerance to one another = +1 mm.

10.14 Compact alternator with poly V-belt

drive 05.99 ▸
From model year 2000 compact alternators with a revised shape
and different terminal designation have been introduced.
External distinguishing features of new compact alternators com‐
pared to the previously used compact alternators are:
♦ Revised voltage regulator.
♦ Oval, radially sealed socket for 2-pin connector housing in‐
stead of previous square 2-pin socket.
♦ Modified terminal designation for connections ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations
olkswagen AG
en AG. V
10.14.1 Securing B+ (battery positive) wire to al‐ yV
olks
wag does
not
gu
ternator d b ara
ise nte
or th eo
au ra
c
ss

ce
e

Note
nl

pt
du

an
itte

y li
♦ The threaded connection for the + wire on the compact alter‐
erm

ab
ility
nator is designated B1+!
ot p

wit
, is n

♦ If the B1+ wire is not secured to the specified torque setting, h re

hole

the following may occur: spec

es, in part or in w

♦ The battery will not be charged fully.

t to the co

♦ Vehicle electrics or electronics fail completely (breakdown).

rrectness of i

♦ Danger of fires from sparks.

l purpos

♦ Damage to electronic components and control units due to

excessive voltage.
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

104 Rep. Gr.27 - Starter, current supply, CCS

 AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or e
h
aut Transporter 1991 ➤ , Transporter 1996or➤ ac
s
s Electrical system - Edition 10.2004

ce
e
nl

pt
du

an
itte
– Tighten threaded connections to specified torque settings

y li
erm

ab
⇒ page 120 .

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

o
10.14.2 Removing and installing voltage regula‐

rm
m

atio
m
tor for alternator 05.99 ▸
o

n in
or c

thi
e

From model year 2000 compact alternators with a revised shape

t

sd
iva

and different terminal designation have been introduced.

o
r
rp

cu
o

m
f

en
ng

External distinguishing features of new compact alternators com‐

t.
yi Co
pared to the previously used compact alternators are: Cop py
t. rig
gh ht
yri
♦ Revised voltage regulator. p by
o Vo
by c lksw
cted agen
♦ Oval, radially sealed socket for 2-pin connector housing in‐ Prote AG.
stead of previous square 2-pin socket.
♦ Modified terminal designation for connections ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations
Removing:
– Unscrew securing nuts -arrows A- and remove securing bolt
-arrow B- for protective cap and remove protective cap.

– Remove voltage regulator securing bolts -arrows- and remove

voltage regulator.
Installing:
Install in the reverse order of removal. When doing this, note the
following:
– Tighten threaded connections to specified torque settings
⇒ page 120 .

10. Alternator with poly V-belt 105

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

10.14.3 Checking alternator carbon brushes

05.99 ▸
Length of new carbon brushes = 12 mm
Wear limit = 5 mm
Carbon brush tolerance to one another = +1 mm.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
10.15 Renewing poly V-belt pulley without

ce
e
nl

pt
du

an
freewheel on alternator
itte

y li
erm

ab
ility
Special tools and workshop equipment required
ot p

wit
, is n

♦ Torque wrench -V.A.G 1332-

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
a

♦ Socket -3310-
iv

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

106 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

10.15.1 Removing and installing poly V-belt pul‐

ley without freewheel on alternator
– Loosen or tighten poly V-belt pulley securing nut with socket
-3310- . To do this, counterhold alternator shaft with multi-point
bit.

10.16 Renewing poly V-belt with freewheel

Note
. Volkswagen AG
♦ A freewheel belt pulley can be retrofitted in vehicles fitted with kswagen AG does
a Bosch alternator ▸ 04.99.
not
Vol gu
by ara
ed nte
ris
♦ A freewheel belt pulley cannot be retrofitted in vehicles
th with a
o eo
Valeo alternator ▸ 04.99. ss
au ra
c

ce
e

♦ Valeo alternators must be renewed complete for a Bosch al‐

nl

pt
du

an
ternator.
itte

y li
erm

ab
♦ On alternators 05.99 ▸ the belt pulley with freewheel is the

ility
ot p

same on all alternators used (different manufacturers).

wit
, is n

h re
hole

spec
10.16.1 Removing and installing poly V-belt pul‐
es, in part or in w

ley with a freewheel

t to the co
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1332- rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

10. Alternator with poly V-belt 107

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

♦ Adapter -3400-

– First remove installed poly V-belt pulley.

– Insert adapter -3400- in freewheel pulley.
– First screw freewheel pulley by hand onto alternator drive shaft
to stop.
Before installing freewheel pulley, set up torque wrench as fol‐
lows:
– Release socket drive -1- and pull off grip -2-.
– Turn torque wrench grip -2- 180° and reinsert socket drive.
– Set turning direction of torque wrench to anti-clockwise at
socket drive.
– Set torque wrench tightening torque to 80 Nm.
– Fit 6 mm Allen key into alternator drive shaft.

AG. Volkswagen AG d
agen oes
olksw no
– Counterhold adapter -3400- d by Vwith 17 mm ring spanner and t gua
ran
tighten freewheel discorby
is turning alternator drive shaft anti-
e
tee
clockwise with torque
au wrench.
th or
ac
ss
– Clip protective cap onto freewheel pulley.
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

108 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

11 Repairing alternator

11.1 65 A - Valeo version with poly V-belt drive

1 - Hexagon nut
❑ 40 Nm
2 - Washer
3 - Belt pulley
❑ Diameter 70 mm.
❑ Removing and installing
⇒ page 111 . agen
AG. Volkswagen AG d
oes
olksw not
4 - Spacer ed byV gu
ara
ris nte
5 - Washer aut
ho eo
ra
ss c
6 - Fan gear

ce
le
un

pt
❑ Note direction of rota‐

an
d
itte

y li
tion, marked by arrow
erm

ab
ility
ot p

7 - Washer

wit
is n

h re
8 - Intermediate ring
ole,

spec
urposes, in part or in wh

9 - Bearing plate

t to the co
❑ Marking position rela‐
tive to alternator hous‐
ing

rrectne
10 - Ball bearing (drive side)

s
❑ Removing and installing

s o
⇒ page 111 .
cial p

f inform
11 - Securing ball bearing
mer

atio
m

12 - Intermediate ring
o

n
c

i
or

n
13 - Semi-round key
thi
te

sd
iva

o
r

14 - Rotor
p

cum
r
fo

en
ng

❑ Checking earth connec‐ yi

t.
Co
tion ⇒ page 111 ht. Cop py
rig
❑ Checking winding short rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

11. Repairing alternator 109

 n AG. Volkswagen AG do
lkswage es n
Vo ot g
Transporter e1991 d by ➤ , Transporter 1996 ➤ ua
ran
ir s
Electricalth system - Edition 10.2004
o tee
or
au ac
ss
or open circuit

ce
e
nl

pt
⇒ page 112
du

an
itte

y li
erm

15 - Ball bearing (slip ring side)

ab
ility
ot p

❑ Removing and installing ⇒ page 111 .

wit
, is n

h re
16 - Stator
hole

spec
❑ Removing and installing ⇒ page 112 .
es, in part or in w

t to the co
❑ Checking earth connection ⇒ page 112
❑ Checking open circuit ⇒ page 112

rrectness of i
17 - Metal ring
l purpos

18 - Plastic bush
❑ Always use new bush

nf
ercia

o
19 - Alternator housing

rm
m

atio
m

20 - Cover
o

n in
or c

21 - Diode plate

thi
te

sd
iva

❑ Removing and installing ⇒ page 112 .

o
r
rp

cu
o

m
❑ Checking ⇒ page 113
f

en
ng

t.
yi Co
op
22 - Voltage regulator
C py
t. rig
gh ht
yri
❑ Removing and installing ⇒ page 110 . p by
co Vo
by lksw
cted agen
23 - Stud Prote AG.

❑ Securing, tensile relaxation of B+ and D+ wires, 3 Nm

24 - Decoupling capacitor
❑ 2.2 mF, 110 V

Decoupling capacitor connection

Plug B+ -arrow-

Removing and installing voltage regulator

The voltage regulator can be removed without removing the al‐
ternator.

110 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Alternator carbon brushes

Length of new carbon brushes: 12 mm
Wear limit: 5 mm
Relative tolerance: +1 mm

Removing and installing ball bearing

1 - Removal device, e.g. Kukko 15/0 or 17/0
2 - Puller, e.g. Kukko 18/0

Note

♦ When installing, press ball bearing through inside ring up to

stop.
n AG. Volkswagen AG do
wage es n
♦ Always use new
y V bearing.
olks ot g
ua
b
ed ran
oris tee
th or
au ac
ss
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec

Removing and installing belt pulley.

es, in part or in w

t to the co

– Hold belt pulley fast with strap wrench.

– Unscrew hexagon nut.
rrectness of i

– Tighten threaded connections to specified torque settings

l purpos

⇒ page 120 .
nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

Rotor - checking earth connection

um
fo

en
ng

t.
yi
– Press button for resistance measurement on hand multimeter
Co
op py
-V.A.G 1526 B- . t. C rig
gh ht
pyri by
An arbitrary resistance value must flash in the kΩ measurement
co Vo
by lksw
cted
range.
agen
Prote AG.

11. Repairing alternator 111

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Rotor - checking winding short or open circuit

– Press button for resistance measurement on hand multimeter
-V.A.G 1526/B- .
Resistance: 2.8 to 3.0 Ω
Open circuit: An arbitrary resistance value flashes in the kΩ
measurement range.
Winding short circuit: Resistance value is not attained.

Removing and installing stator and diode plate

– Use needle-nose pliers to dissipate heat at the soldering
points -arrows-.
– Use radio solder and max. 300 W soldering iron.
– Desolder stator windings.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut
Stator - checking earth connection
ss a ra
c
ce
e

– Press button for resistance measurement on hand multimeter

nl

pt
du

-V.A.G 1526/B- . an
itte

y li
erm

ab
– Connect measuring cables consecutively to measuring points ility
ot p

at 1 and 2; 1 and 3; 1 and 4.

wit
, is n

h re

An arbitrary resistance value must flash in the kΩ measurement

hole

spec

range.
es, in part or in w

t to the co
rrectness of i
l purpos

Stator - checking open circuit

nform
ercia

– Press button for resistance measurement on hand multimeter

-V.A.G 1526/B- .
m

at
om

io

– Route measuring lines consecutively to winding ends at 1 and

n
c

in t
r

2; 1 and 3; 2 and 3.
o

his
ate

do
riv

The gauge must indicate approximately 0 ohms at each meas‐

p

cum
or

urement.
f

en
ng

t.
yi Co
In case of an open circuit an arbitrary resistance value must flash Cop py
in the kΩ measurement range.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

112 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Checking diode plate

– Simultaneously press buttons for resistance and voltage
measurement on hand multimeter -V.A.G 1526 B- .
– Check positive diodes: consecutively connect black terminal
to positive heat sink -1- (corresponds to B+) and red terminal
to collective points -2-.
– Check negative diodes: consecutively red terminal to negative
heat sink -3- and black terminal to collective points n-2-.
AG. Volkswagen A ge G do
swa es n
– Check exciter diodes: consecutively blackbyterminal
Vol
k
to contact ot g
ua
rail -4- (corresponds to D+) and red terminal
ir se
d to collective points ran
tee
-2-. ut
ho or
a ac
ss
All tests must indicate 50 - 80 Ω 3 times; renew diode plate in case

ce
e
nl

of deviation.

pt
du

an
itte

y li
erm

ab
11.2 90 A - Bosch version with poly V-belt

ility
ot p

wit
drive
, is n

h re
hole

spec
– Tighten threaded connections to specified torque settings
es, in part or in w

⇒ page 120 .

t to the co
1 - Hexagon nut

rrectness of i
❑ 50 Nm
l purpos

2 - Washer
3 - Belt pulley

nform
ercia

❑ Diameter 74 mm.
m

at
om

i
❑ Removing and installing

on
c

⇒ page 115 .

in t
or

his
ate

4 - Spacer

do
priv

cum
or

5 - Washer
f

en
ng

t.
yi Co
op
6 - Fan gear
C py
t. rig
gh ht
yri
❑ Note direction of rota‐ p by
co Vo
lksw
tion, marked by arrow
by
cted agen
Prote AG.
7 - Cross-head screw
❑ M4×20
8 - Cross-head fillister head
bolt
❑ M5×105
9 - Bearing plate
❑ Marking position rela‐
tive to alternator hous‐
ing
10 - Ball bearing (drive side)
❑ Removing and installing

11. Repairing alternator 113

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

⇒ page 116 .
11 - Securing ball bearing
12 - Intermediate ring
13 - Semi-round key
14 - Rotor
❑ Checking earth connec‐
tion ⇒ page 117
❑ Checking winding short or open circuit ⇒ page 117 AG. Volkswagen AG d
agen oes
lksw not
15 - Ball bearing (slip ring side) d by Vo gu
ara
❑ Removing and installing ⇒ page 116 . rise nte
tho eo
au ra
16 - Stator ss c

ce
le
un
❑ Removing and installing ⇒ page 116 .

pt
an
d
itte

y li
❑ Checking earth connection ⇒ page 116
erm

ab
❑ Checking open circuit ⇒ page 116

ility
ot p

wit
is n

17 - Allen head bolts

h re
ole,

❑ M4×20

spec
urposes, in part or in wh

t to the co
18 - Diode plate
❑ Checking ⇒ page 117

rrectne
19 - Plastic insulating washer
20 - Plastic grease bush

ss
❑ Always use new bush

o
cial p

f inform
21 - Alternator housing
mer

atio
22 - Voltage regulator
om

n
c

❑ Removing and installing ⇒ page 115 .

i
or

n thi
te

sd
❑ Checking carbon brushes ⇒ page 115 .
iva

o
pr

cum
r

23 - Plastic insulating base

fo

en
ng

t.
yi Co
24 - Allen head bolts Cop py
t. rig
gh
❑ M5×10
ht
pyri by
Vo
co lksw
by
cted
25 - Washer
agen
Prote AG.

26 - Spring ring
27 - Washer
28 - Hexagon nut
❑ D+, M5, 3 Nm
29 - Spring ring
30 - Hexagon nut
❑ B+, M8, 16 Nm
31 - Decoupling capacitor
❑ 2.2 mF, 110 V
32 - Allen head bolt
❑ M5×10

114 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Decoupling capacitor connection

Plug B+ -arrow-

Removing and installing voltage regulator

The voltage regulator can be removed without removing the al‐
ternator.

AG. Volkswagen AG d
agen oes
olksw not
Checking carbon brushes d byV gu
ara
ise nte
r
Length of new carbon brushes:ut12
h mm
o eo
ra
s a c
Wear limit: 5 mm s
ce
le
un

pt
Relative tolerance: +1 mm an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
m

Removing and installing belt pulley.

o

n
c

i
or

– Counterhold with hexagon socket bolt

thi
te

sd
iva

o
r

– Tighten threaded connections to specified torque settings

p

cum
r
fo

⇒ page 120 .
en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

11. Repairing alternator 115

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Removing and installing ball bearing

1 - Removal device, e.g. Kukko 15/0 or 17/0
2 - Puller, e.g. Kukko 18/0

Note

♦ When installing, press ball bearing through inside ring up to

stop.
♦ Always use new bearing.

Removing and installing stator and diode plate

– Use needle nose pliers to dissipate heat at the soldering points
-arrow-.
– Use radio solder and max. 300 W soldering iron.
– Desolder stator windings.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or
Stator - checking earth connection aut
h eo
ra
ss c
– Press button for resistance measurement on hand multimeter ce
e
nl

pt
-V.A.G 1526 B- .
du

an
itte

y li
– Route measuring lines consecutively to measuring points at 1
erm

ab
ility
and 2; 1 and 3; 1 and 4; 1 and 5.
ot p

wit
, is n

An arbitrary resistance value must flash in the kΩ measurement

h re
hole

range.
spec
es, in part or in w

t to the co
rrectness of i

Stator - checking open circuit

l purpos

– Press button for resistance measurement on hand multimeter

nform

-V.A.G 1526 B- .
mercia

– Route measuring lines consecutively to winding ends at 1 and

at
om

io

2; 1 and 3; 1 and 4; 2 and 3; 2 and 4; 3 and 4.

n
c

in t
or

The gauge must indicate approximately 0 ohms at each meas‐

his
ate

do
riv

urement.
p

cum
for

Open circuit: An arbitrary resistance value flashes in the kΩ

en
ng

t.
yi
measurement range.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

116 Rep. Gr.27 - Starter, current supply, CCS

 AG. Volkswagen AG d
agen oes
ksw not
by Vol
gu
ara
Transporter 1991 ➤ , Transporter 1996 ➤
d
rise nte Electrical system - Edition 10.2004
ho eo
aut ra
ss c
Rotor - checking earth connection

ce
le
un

pt
– Press button for resistance measurement on hand multimeter

an
d
itte

y li
-V.A.G 1526 B- .
erm

ab
ility
ot p

An arbitrary resistance value must flash in the kΩ measurement

wit
is n

range.

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness
Rotor - checking winding short or open circuit

o
cial p

f in
– Press button for resistance measurement on hand multimeter

form
mer

-V.A.G 1526 B- .

atio
om

Resistance: 2.8 to 3.0 Ω

n
c

i
or

n thi
e

Open circuit: An arbitrary resistance value flashes in the kΩ

t

sd
iva

o
measurement range.
pr

cum
r
fo

en
ng

Winding short circuit: Resistance value is not attained.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Checking diode plate

– Simultaneously press buttons for resistance and voltage
measurement on hand multimeter -V.A.G 1526 B- .
– Check positive diodes: consecutively connect black terminal
to positive heat sink -1- (corresponds to B+) and red terminal
to collective points -2-.
– Check negative diodes: consecutively red terminal to negative
heat sink -3- and black terminal to collective points -2-.
– Check exciter diodes: consecutively black terminal to contact
rail -4- (corresponds to D+) and red terminal to collective points
-2-.
All tests must indicate 50 - 80 Ω 3 times; renew diode plate in case
of deviation.

11.3 70 A, 90 A and 120 A alternator with poly

V-belt
– Tighten threaded connections to specified torque settings
⇒ page 120 .

11. Repairing alternator 117

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1 - Hexagon nut M16×1.5

❑ 65 Nm
2 - Spring ring
3 - Poly V-belt pulley
❑ Removing and installing
⇒ page 119 .
4 - Alternator
5 - Voltage regulator
❑ Checking carbon brush‐
es ⇒ page 119 .
6 - Fillister head bolts with
cross head M4×25
7 - Protective cap
8 - Hexagon bolts M3×18

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

118 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system
- Edition 10.2004
n AG. Volkswagen AG do
lkswage es n
o ot g
Special tools and work‐ d byV ua
ran
shop equipment re‐ ir se tee
ho
quired aut or
ac
ss
♦ Torque wrench -

ce
le
un

pt
V.A.G 1332-

an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f
♦ Socket -VAS 3310-

inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Removing and installing

poly V-belt pulley
Special tool socket 3310
is required for loosening
or fastening the poly V-
belt pulley at the alterna‐
tor.

Checking voltage regulator carbon brushes

Length of new carbon brushes: 12 mm
Wear limit: 5 mm
Relative tolerance: +1 mm

11. Repairing alternator 119

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

12 Alternator torque settings

12.1 General torque settings

Threaded connections Torque settings
B+ wire securing nut to alternator with push-on M8 15 Nm
connector for ▸ 04.99
B+ wire securing nut to alternator with screw-on M8 15 Nm
connector for wire ▸ 04.99
D+ wire securing nut to alternator 3.2 Nm
B1+ wire securing nut to alternator 05.99 ▸ M8 15 Nm
Poly V-belt pulley securing bolt without free‐ M8 65 Nm
wheel to alternator shaft
Poly V-belt pulley securing bolt with freewheel M8 80 Nm
to alternator shaft
Hexagon nut to 65 A Valeo version, with V-belt 40 Nm
drive -item. No. 1-
Hexagon nut to 90 A Bosch version, with V-belt 50 Nm
drive -item No. 1-
Belt pulley hexagon nut 70 A, 90 A and 120 A 65 Nm
alternator with poly V-belt

12.2 Torque settings: alternator

wage
n with
AG. VolkV-belt
swagen AG
doe
ks s no
Vol t gu
d by ara
e nte
ris
12.2.1 4-cylinder petrol engine ho
t eo
s au ra
c
s
ce
le

Threaded connections Torque settings

un

pt
an
d
itte

y li

Hexagon socket head bolt -item No. 2- M8 35 Nm

rm

ab
pe

ility

Hexagon bolt -item No. 6- M8 30 Nm

ot

wit
, is n

Hexagon bolt -item No. 7- M8 30 Nm

h re
hole

Hexagon bolt -item No. 14- M8 35 Nm

spec
es, in part or in w

Hexagon bolt -item No. 18- M8 20 Nm

t to the co

Hexagon bolt -item No. 20- M8 20 Nm

Tensioning nut with new V-belt 8 Nm
rrectness of i

Tensioning nut with used V-belt 4 Nm

l purpos

Tensioning arm securing bolt 20 Nm

Alternator securing bolts to bracket 35 Nm
nform
ercia

Tensioning nut clamping bolt 35 Nm

m

a
com

tion in
r
te o

thi
s
iva

12.2.2 4-cylinder diesel engine

do
r
rp

cum
fo

en
g

Threaded connections Torque settings

n

t.
yi Co
op py
Hexagon nut -item No. 1- M8 50 Nm
t. C rig
gh ht
pyri by
Hexagon bolt -item No. 9- M8 25 Nm
o Vo
by c lksw
cted agen
Prote
Hexagon bolt -item No. 10- M8 35 Nm
AG.

Hexagon bolt -item No. 14- M8 25 Nm

Hexagon bolt -item No. 16- M8 16 Nm
Hexagon bolt -item No. 17- M8 20 Nm

120 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Threaded connections Torque settings

Hexagon bolt -item No. 18- M8 50 Nm
Tensioning nut with new V-belt 8 Nm
Tensioning nut with used V-belt 4 Nm
Tensioning arm securing bolt 20 Nm
Alternator securing bolts to bracket 35 Nm
Tensioning nut clamping bolt 35 Nm

12.3 4-cylinder engine with 90 A alternator ▸ 04.99

Threaded connections Torque settings
Hexagon nut -item No. 2- M8 30 Nm
Hexagon bolt -item No. 11- M8 23 Nm
Hexagon bolt -item No. 12- gen AGM8
. Volkswagen AG
d
25 Nm
wa oes
olks not
byV gu
ara
ed nte
ris
tho eo
12.4 4-cylinder engine
ss with 90 A alternator 05.99 ▸ au ra
c

ce
le
un

pt
Threaded connections Torque settings

an
d
itte

y li
Hexagon bolt -item No. 1- M8 25 Nm
rm

ab
pe

ility
Hexagon nut -item No. 3- M8 30 Nm
ot

wit
, is n

h re
Hexagon bolt -item No. 14- M8 25 Nm
hole

spec
es, in part or in w

t to the co
12.5 4-cylinder engine with 120 A alternator ▸ 04.99
Threaded connections Torque settings rrectness of i
l purpos

Hexagon bolt -item No. 1- M8 25 Nm

Hexagon socket head bolt -item No. 9- M8 25 Nm
nform
ercia

Hexagon socket head bolt -item No. 10- M8 25 Nm

m

Hexagon bolt -item No. 17- M8 25 Nm

com

tion in
r
te o

thi
s
iva

do
r
rp

12.6 4-cylinder engine with 120 A alternator 05.99 ▸

um
fo

en
ng

t.
yi Co
op
Threaded connections Torque settings
C py
ht. rig
rig ht
Hexagon bolt -item No. 1- M8 25 Nm
py by
co Vo
by lksw
cted
Hexagon socket head bolt -item No. 9- M8 25 Nm
agen
Prote AG.

Hexagon socket head bolt -item No. 10- M8 25 Nm

Hexagon bolt -item No. 19- M8 25 Nm

12.7 4-cylinder engine with air conditioner compressor or 2nd alternator ▸ 04.99
Threaded connections Torque settings
Hexagon bolt -item No. 1- M8 25 Nm
Hexagon bolt -item No. 3- M8 25 Nm
Hexagon nut -item No. 6- (always renew) M8 33 Nm
Hexagon bolt -item No. 13- M8 25 Nm

12. Alternator torque settings 121

 AG. Volkswagen AG d
Transporter 1991 ➤ , Transporter 1996 ➤ ksw
agen oes
not
ol
Electrical system - Edition 10.2004 d byV gu
ara
ise nte
or eo
h
ut
Threaded connections ss a Torque settings ra
c

ce
le
Stud bolts with hexagon -item No. 14- M8 25 Nm

un

pt
an
d
itte

y li
erm

ab
ility
ot p
12.8 4-cylinder engine with air conditioner compressor or 2nd alternator 05.99 ▸

wit
is n

h re
ole,

spec
Threaded connections Torque settings

urposes, in part or in wh

t to the co
Hexagon bolt -item No. 1- M8 25 Nm
Hexagon bolt -item No. 3- M8 25 Nm
Hexagon nut -item No. 6- (always renew) M8 33 Nm

rrectne
Hexagon bolt -item No. 15- M8 25 Nm

s
Stud bolts with hexagon -item No. 16- M8 25 Nm

s o
cial p

f inform
mer

atio
m

12.9 5-cylinder engine without air conditioner or 2nd alternator ▸ 04.99

o

n
c

i
or

n thi
e

Threaded connections Torque settings

t

sd
iva

o
pr

cum
Hexagon bolts -item No. 1- M8 40 Nm
r
fo

en
ng

t.
yi
Hexagon socket head bolt -item No. 2- M8 40 Nm
Co
Cop py
. rig
Hexagon bolts -item No. 4- M8 40 Nm
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

12.10 5-cylinder engine without air conditioner or 2nd alternator 05.99 ▸

Threaded connections Torque settings
Hexagon bolts -item No. 1- M8 40 Nm
Hexagon socket head bolt -item No. 2- M8 40 Nm
Hexagon bolts -item No. 4- M8 40 Nm

12.11 5-cylinder engine with air conditioner or 2nd alternator or hydraulic pump ▸
04.99
Threaded connections Torque settings
Hexagon bolts -item No. 7- M8 40 Nm
Hexagon socket head bolt -item No. 9- M10 40 Nm
Hexagon bolts -item No. 10- M10 40 Nm
Hexagon socket head bolt -item No. 11- M8 20 Nm
Hexagon bolts -item No. 12- M8 25 Nm
Bolt with washer -item No. 13- M10 40 Nm

12.12 5-cylinder engine with air conditioner or 2nd alternator or hydraulic pump
05.99 ▸
Threaded connections Torque settings
Hexagon bolts -item No. 9- M8 40 Nm
Hexagon bolt -item No. 11- M10 40 Nm
Hexagon bolts -item No. 12- M10 40 Nm
Hexagon socket head bolt -item No. 13- M8 20 Nm

122 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Threaded connections Torque settings

Hexagon bolts -item No. 14- M8 25 Nm
Bolt with washer -item No. 15- M10 40 Nm
Hexagon bolts -item No. 16- M8 25 Nm

12.13 6-cylinder fuel injection engine ▸ 04.99

Threaded connections Torque settings
Hexagon bolts -item No. 1- M8 25 Nm
Hexagon socket bolt and washer assemblies M8 25 Nm
-item No. 3-
Fitted bolt -item No. 5- M8 25 Nm
Hexagon bolt -item No. 6- M8 25 Nm
Fitted bolt -item No. 14- M8 25 Nm
Hexagon socket bolt and washer assembly M8 25 Nm
-item No. 16-
Hexagon socket bolt and washer assembly M8 25 Nm
-item No. 17-

12.14 6-cylinder fuel injection engine 05.99 ▸

Threaded connections Torque settings
Hexagon bolts -item No. 1- M8 25 Nm
Hexagon socket bolt and washer assemblies M8 25 Nm
-item No. 3- n AG. Volkswagen AG
wage does
Fitted bolt -item No. 5- olks n
by V M8 25 Nm ot gua
ed ran
Hexagon bolt -item No. 6- tho
ris M8 25 Nm tee
u or
Fitted bolt -item No. 16- ss
a
M8 25 Nm ac
ce
le

Hexagon socket bolt and washer assembly M8 25 Nm

un

pt
an
d

-item No. 18-

itte

y li
erm

ab

Hexagon socket bolt and washer assembly M8 25 Nm

ility
ot p

-item No. 19-

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

12. Alternator torque settings 123

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

13 Cruise control system (CCS)

13.1 Cruise control system (CCS) for vehi‐

cles with electronic accelerator
In vehicles with electronic accelerators the function of the cruise
control system is controlled by the injection control unit.
Apart from the cruise control system operating switch in turn sig‐
nal lever there are no additional components.
Repairing the CCS ⇒ Workshop manual for corresponding fuel
injection system ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations

13.2 Cruise control system (CCS) for vehi‐

cles without electronic accelerator swage
n AG. Volkswagen AG do
es n
olk ot g
byV ua
d ran
ir se
Caution tho tee
or
au ac
ss
To disconnect and connect the battery, the procedure descri‐

ce
le
un

pt
bed in the workshop manual should be strictly adhered to

an
d
itte

⇒ page 29 .

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

124 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1 - Relay plate
❑ Removing and installing
2 - Cruise control system AG. Volkswagen AG d
switch -E45- agen oes
olksw not
V gu
by
❑ Removing and installing rised ara
nte
⇒ page 215 . ut
ho eo
r
sa ac
3 - Bracket for vacuum spump

ce
le
un

pt
4 - Vacuum lines

an
d
itte

y li
erm

❑ Leak test ⇒ page 127

ab
ility
ot p

5 - M5 hexagon nut

wit
is n

h re
❑ 3 Nm
ole,

spec
urposes, in part or in wh

6 - Cruise control system vac‐

t to the co
uum pump -V18-
❑ Removing ⇒ page 127 .

rrectne
7 - M8 hexagon nut
❑ 16 Nm

ss o
8 - Washer
cial p

f inform
9 - Accelerator positioning ele‐
mer

ment

atio
om

❑ Removing ⇒ page 126 .

n
c

i
or

n thi
e

❑ Adjusting ⇒ page 126 .

t

sd
iva

o
pr

c
10 - Cross-head screw

um
r
fo

en
ng

t.
yi
11 - Cruise control system con‐
Co
op py
trol unit t. C rig
gh ht
yri by
❑ Behind dash panel on op Vo
by c lksw
right cted agen
Prote AG.
❑ Removing ⇒ page 127 .
12 - Accelerator
13 - Pop rivet
14 - Positioning element bracket
❑ riveted to pedal cluster
15 - Plastic nut
❑ 3 Nm
16 - Cruise control system wiring harness
17 - Vacuum line junction piece
18 - Vent valve with brake pedal switch -F47-
❑ Removing and installing ⇒ page 126 .
19 - Vent valve with clutch pedal switch -F36-
❑ Removing and installing ⇒ page 126 .
20 - Fastener

13. Cruise control system (CCS) 125

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

13.3 Adjusting positioning element

– Hold accelerator pedal -1- in idling position.
– Pull adjusting sleeve -2- with pull rod -3- in direction of arrow
until resistance is felt.
– Lock adjusting sleeve by turning.
– Check ease of movement of accelerator pedal.

13.4 Removing positioning element

1 - Positioning element
2 - Plastic nut
3 - Positioning element bracket
4 - Pop rivet
5 - Pedal cluster . Volkswagen AG
gen AG does
swa
6- Ball head pin, at accelerator pedal yV
olk not
gu
d b ara
e nte
7- Spacer - only on vehicles with automatic
horis
gearbox eo
aut ra
– Disconnect vacuum line from positioning
ss element -1-. c

ce
e
nl

pt
– Unclip positioning element pull rod ball head pin -6-.
du

an
itte

y li
erm

– Unscrew plastic nut -2- and remove positioning element -1-.

ab
ility
ot p

wit
, is n

13.5 Removing and installing vent valve h re

hole

spec
1 - Vacuum lines
es, in part or in w

t to the co

2 - Vent valve at clutch pedal

3 - Positioning element
rrectness of i

4 - Vent valve at brake pedal

l purpos

Removing:
nf
ercia

– Pull off connector and vacuum line.

orm
m

– Remove vent valve from bracket.

atio
om

n in
c

Installing:
or

thi
te

sd
a

– Screw vent valve into bracket onto stop. The pedal must be
iv

o
r
rp

cu

pulled all the way back.

o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

126 Rep. Gr.27 - Starter, current supply, CCS

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

13.6 Removing and installing cruise control

system (CCS) vacuum pump -V18-
– Pull off connector and vacuum line from vacuum pump -1-.
– Remove hexagon bolt -2-.
– Remove vacuum pump -1- completely with bracket.

13.7 Removing and installing cruise control

system (CCS) control unit -J213-
– Remove glove box.
– Unscrew assembly plate with control unit -1- and relay
-arrows-.
– Pull off connector -2- from control unit -1-.
– Remove control unit with assembly plate.

AG. Volkswagen AG d
13.8 Checking vacuum system for leaks Volksw
agen oes
not
gu
by ara
d
– Pull vacuum line off vacuum pump and seal. orise nte
eo
th
au ra
– Press in diaphragm at positioning element by pressing
ss brake c
pedal by hand to the pressure point. ce
e
nl

pt
du

an
itte

– Then release brake pedal. y li

erm

ab

– The diaphragm must not move.

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
127
Prote AG.
13. Cruise control system (CCS)
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

90 – Gauges, instruments
1 Dash panel insert ▸ 12.95

1.1 Removing and installing dash panel in‐

sert

Caution

To disconnect and connect the battery, the procedure descri‐

bed in the workshop manual should be strictly adhered to
⇒ page 29 .

Note

♦ Pull off multi-pin connector and speedometer drive shaft with‐

out removing housing.
♦ The instruments, warning lamps with plug-in bulb holders and
the illumination bulbs can be removed like the voltage stabil‐
iser without removing the housing.
♦ The bulbs for the multi-function indicator/digital clock, odom‐
eter display and selector lever display, the contact contact
plate with speed sender G54 and the multi-function indicator
pressure sender can be removed only after removal of the
housing.

Remove steering wheel:

– Unclip cover cap -1-. AG. Volkswagen AG d
agen oes
lksw not
– Unscrew hexagon nut -2- (70 Nm). d byV
o gu
ara
ise nte
r
– Mark steering wheel position and remove
ut
ho steering wheel -3-. eo
ra
s a c
Remove steering column switch ands trim:
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw

128
cted agen
Prote AG.
Rep. Gr.90 - Gauges, instruments
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Unscrew cross-head screws -1- and remove trim -2-.

– Pull off connectors at steering column switch -4-.
– Unscrew cross-head screws -5- and pull off steering column
switch-4-.
– Remove trim -3-.
Remove dash panel insert cover:

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

– Unscrew two panel screws -1- and remove dash panel insert

wit
is n

cover -2- from spring clips -3-.

h re
ole,

spec
Remove complete dash panel insert:
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

– Unscrew left and right securing bolts -2-. i

or

n thi
te

sd
a

– Pull out dash panel insert from dash panel and pull off multi-
iv

o
pr

pin connector, multi-function indicator pressure sender hose

um
r
fo

and speedometer drive shaft on back of dash panel insert.

en
ng

t.
yi Co
op py
– Loosen transparent cover securing bolts -1-. t. C rig
gh ht
yri by
– Unscrew or pull off trip recorder reset button and pull off trans‐
cop Vo
by lksw
cted
parent cover.
agen
Prote AG.

1.2 Assembly overview - dash panel insert

with rev counter or analogue clock

Note

♦ Fault finding programmes for specific systems and current cir‐

cuits: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
♦ Information on checking voltages, LEDs and bulbs with test
box (basic unit) -V.A.G 1598/14- ⇒ page 138 .

1. Dash panel insert ▸ 12.95 129

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1 - Transparent cover
2 - Rev counter -G5-
❑ Note different versions
❑ Removing and installing
instruments
⇒ page 134 .
3 - Speed sender (at dash pan‐
el insert) -G54- , mechanical
❑ Removing and installing
instruments
⇒ page 134 .
❑ Removing and installing
AG. Volkswagen AG d
drive shaft ksw
agen oes
not
l
⇒ page 138 . byV
o gu
ara
ed
❑ Installing speed sender horis nte
eo
(at dash panel insert) - s aut ra
c
G54- ⇒ page 139 s

ce
le
un

pt
4 - Coolant temperature gauge

an
d
itte

y li
-G3- and fuel gauge -G1- with
erm

ab
cut-out for digital clock -Y2- or

ility
ot p

4 A - coolant temperature

wit
is n

gauge -G3- and fuel gauge -

h re
ole,

G1-

spec
urposes, in part or in wh

❑ Removing and installing

t to the co
instruments
⇒ page 134 .
5 - Right turn signal warning

rrectne
lamp -K94-
❑ Checking LED

ss o
⇒ page 138
cial p

f in
❑ Installing ⇒ page 135

form
mer

atio
6 - Right warning lamps
om

n
c

❑ Installation position
i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

130 Rep. Gr.90 - Gauges, instruments

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

⇒ page 134
❑ Checking LED ⇒ page 138
❑ Installing ⇒ page 135
7 - Analogue clock -Y-
Volkswagen AG
❑ Removing and installing instruments ⇒ page 134s.wagen AG. does
k not
Vol g
by
8 - Printed circuit board for analogue clock or 8 sAedprinted circuit board with digital clock
ua
ran
ri tee
❑ Renewing printed circuit board only in autcombination with housing
ho
or
ac
❑ Components on printed circuit board ss ⇒ page 136

ce
le
un

pt
9 - Voltage stabiliser -J6- with cooling panel

an
d
itte

y li
❑ Checking ⇒ page 135 erm

ab
ility
ot p

❑ Removing and installing ⇒ page 136 .

wit
is n

h re
10 - Housing
ole,

spec
❑ Renewing housing only in combination with printed circuit board
urposes, in part or in wh

t to the co
11 - Contact plate for speed sender (at dash panel insert) -G54-
❑ Installing speed sender ⇒ page 139

rrectne
12 - Bulb for digital clock illumination
❑ Black bulb holder

ss o
❑ 12 V/1.2 W
cial p

f in
❑ Installation position ⇒ page 137

form
mer

❑ Removing and installing ⇒ page 137 .

atio
om

n
c

13 - Left warning lamps

i
or

n thi
te

❑ Installation position ⇒ page 134

sd
iva

o
pr

c
❑ Checking LED ⇒ page 138

um
r
fo

en
ng

❑ Installing ⇒ page 135

t.
yi Co
Cop py
t. rig
14 - Left turn signal warning lamp -K65- opyri
gh by
Vo
ht

❑ Checking LED ⇒ page 138

c by lksw
cted agen
Prote AG.
❑ Installing ⇒ page 135
15 - Conductor strip for illumination, dash panel insert
❑ Printed circuit board connector ⇒ page 136
16 - Bulb for dash panel insert illumination -L10-
❑ Blue bulb holder
❑ 12 V/1.2 W
17 - Speed sender (at dash panel insert) -G54-
❑ Only with mechanical speedometer
❑ Installing ⇒ page 139

1.3 Assembly overview - dash panel insert

with multi-function indicator (MFI)

Note

♦ Fault finding programmes for specific systems and current cir‐

cuits: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
♦ Information on checking voltages, LEDs and bulbs with test
box (basic unit) -V.A.G 1598/14- ⇒ page 138 .

1. Dash panel insert ▸ 12.95 131

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1 - Transparent cover
2 - Rev counter -G5-
❑ Note different versions
❑ Removing and installing
instruments
⇒ page 134 .
3 - Speedometer -G21- , elec‐
tronic
❑ Removing and installing
instruments
⇒ page 134 .
❑ Removing and installing
speedometer -G22-
⇒ page 136
4 - Coolant temperature gauge
-G3- and fuel gauge -G1- with
cut-out for multi-function indi‐
cator -J119- n AG. Volkswagen AG do
wage
❑ Removing and installing olks es n
ot g
yV
instruments d b ua
ran
ir se
⇒ page 134 . tho tee
or
au ac
5 - Right turn signal warning ss

ce
e

lamp -K94-
nl

pt
du

an
itte

❑ Checking LED

y li
erm

ab
⇒ page 138

ility
ot p

❑ Installing ⇒ page 135

wit
, is n

h re
6 - Right warning lamps
hole

spec
❑ Installation position
es, in part or in w

t to the co
⇒ page 134
❑ Checking LED

rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

132 Rep. Gr.90 - Gauges, instruments

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

⇒ page 138
❑ Installing ⇒ page 135
7 - Printed circuit board
❑ Renewing printed circuit board only in combination with housing
❑ Components on printed circuit board ⇒ page 136 , ⇒ page 136
8 - Bulbs for illuminating odometer display, multi-function indicator (MFI) or selector lever display
❑ Black bulb holder
❑ 12 V/1.2 W
❑ Installation position ⇒ page 137
❑ Removing and installing ⇒ page 137 .
9 - Housing
❑ Renewing only in combination with printed circuit board
10 - Pressure sender for multi-function indicator -G55-
❑ Removing ⇒ page 138 .
❑ Removing dash panel insert beforehand ⇒ page 128
11 - Left warning lamps
❑ Installation position ⇒ page 134
❑ Checking LED ⇒ page 138
❑ Installing ⇒ page 135
12 - Left turn signal warning lamp -K65- AG. Volkswagen AG d
agen
❑ Checking LED ⇒ page 138 Volksw
oes
not
gu
by ara
❑ Installing ⇒ page 135 rised
nte
ho eo
ut
13 - Conductor strip for dash panel insert
ss aillumination ra
c
❑ Components on printed circuit board, back ⇒ page 136 , ⇒ page 136

ce
le
un

pt
an
d
itte

14 - Bulb for dash panel insert illumination -L10-

y li
erm

ab
❑ Blue bulb holder

ility
ot p

wit
❑ 12 V/1.2 W
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Dash panel insert ▸ 12.95 133

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1.4 Dismantling and assembling dash panel

insert
1.4.1 Removing and installing instruments

Caution

To disconnect and connect the battery, the procedure descri‐

bed in the workshop manual should be strictly adhered to
⇒ page 29 .

Note

Before working on components in the dash panel insert, discon‐

nect the battery earth strap.

1 - Fuel gauge and coolant temperature gauge

- additionally with digital clock or multi-function indicator (MFI)
2 - Mechanical speedometer or electronic speedometer -G21-
3 - Analogue clock or rev counter
- Additionally with selector lever display
n AG. Volkswagen AG do
swage es n
– Pull instruments -1 and 3- forwards out of housing; likewise by Vo lk ot g
ua
with instrument -2- (electronic speedometer). ir se
d ran
tee
tho
or
– Mechanical speedometer: loosen -2- securing bolts -B- auand ac
ss
pull out instrument forwards.

ce
le
un

pt
an
d
itte

y li
1.4.2 Installation positions of left warning
erm

ab
ility
lamps
ot p

wit
is n

h re
1 - Coolant temperature/coolant shortage indicator warning lamp
ole,

spec
(red), LED
urposes, in part or in wh

t to the co
2 - No connection
3 - Oil pressure warning lamp (red), LED

rrectne
4 - Main beam warning lamp (blue), bulb
ss o
cial p

f inform
mer

1.4.3 Installation positions of right warning

atio
om

lamps
n
c

i
or

n thi
te

sd
a

1 - Warning lamp (red) for dual circuit brake and handbrake con‐
iv

o
pr

trol, LED
um
r
fo

en
ng

t.
- Seat belt warning system warning lamp (red), LED
yi Co
Cop py
t. rig
2 - Alternator warning lamp (red), LED
gh ht
pyri by
Vo
co lksw
by
3 - Glow period indicator lamp (yellow), LED Prote
cted AG.
agen

- Catalytic converter monitoring warning lamp (red), LED

4 - No connection

134 Rep. Gr.90 - Gauges, instruments

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1.4.4 Installing left/right warning lamps

Replace left and right warning lamps after pulling off top of 4-bulb
holder.

Note

When installing the LEDs make sure polarity corresponds to fig‐

ure on top of bulb holder.

AG. Volkswagen AG d
agen oes
ksw
1.4.5 Installing left/right turn signal warning d byV
ol not
gu
ara
lamps (K65/K94) ise nte
or eo
h
aut ra
s c
Insert turn signal warning lamps according to the adjacent figure. s

ce
e
nl

pt
du

1 - LED

an
itte

y li
erm

ab
2 - Top of bulb holder with catch

ility
ot p

3 - Lower part of bulb holder

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
1.4.6 Checking voltage stabiliser -J6-

rrectness of i
l purpos

Note

nf
ercia

orm
Check only if fuel and coolant temperature gauges give false
m

atio
m

readings. Do not disconnect battery earth strap; multi-pin con‐

o

n in
c

nector remains plugged into dash panel insert.

or

thi
te

sd
iva

o
Check voltage supply:
r
rp

cu
o

m
f

en
ng

– Remove right instrument.

t.
yi Co
Cop py
– Switch on ignition. ht. rig
rig ht
py by
co Vo
– Voltmeter between terminal 15 -a- and earth -b-. Specification:
by lksw
cted agen
Prote
approx. battery voltage
AG.

– If the specification is not attained, check wiring according to

current flow diagram.
Check output voltage:
– Voltmeter between output 15 -c- and earth -b-. Specification:
9.5...10.5 V
– If the specification is not attained, voltage stabiliser is defec‐
tive; renew.

1. Dash panel insert ▸ 12.95 135

 . Volkswagen AG
gen AG does
swa
Transporter 1991 ➤ , Transporter 1996 ➤ yV
olk not
gu
b ara
Electrical system - Edition 10.2004 rised
nte
ho eo
aut ra
1.4.7 Removing and installing voltage stabil‐
ss c

ce
e
nl

pt
iser -J6- (mechanical speedometer)

du

an
itte

y li
erm

ab
– Remove right indicator instrument

ility
ot p

wit
– Unscrew securing bolt -2- and remove voltage stabiliser -1-

, is n

h re
from contacts -a, b, c- downwards.

hole

spec
es, in part or in w

t to the co
Note

When installing make sure that the 3 connections are inserted in

rrectness of i
the contacts -a-, -b-, -c- and that the stabiliser is firmly screwed
onto the cooling panel -3- (heat dissipation from the housing).
l purpos

nform
ercia

1.4.8 Removing and installing speedometer

m

at
sender -G22-
om

ion
c

in t
or

The speedometer sender -G22- is bolted to the gearbox instead

his
ate

of the speedometer drive shaft and supplies 4 pulses per revolu‐

do
priv

c
tion.

um
for

en
ng

t.
yi
– After pulling off connector, loosen sender using suitable
Co
op py
wrench, 22 mm, and unscrew by hand.
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

1.4.9 Components on printed circuit board

front on vehicles with digital clock -Y2-
1 - Printed circuit board
2 - Conductor strip for dash panel insert illumination
3 - Connector for conductor strip
4 - Left/right turn signal warning lamps
5 - Recess for voltage stabiliser bolted on a cooling plate with the
dash panel insert housing
6 - Right warning lamps
7 - Left warning lamps
8 - Digital clock, do not renew separately

1.4.10 Components on printed circuit board

back on vehicles with digital clock -Y2-
1 - Printed circuit board
2 - Oil pressure warning buzzer, do not renew separately
3 - Conductor strip for dash panel insert illumination
4 - Connector for conductor strip
5 - 28-pin connector for dash panel insert wiring harness
6 - Digital clock illumination
7 - Warning lamp bulb holder

136 Rep. Gr.90 - Gauges, instruments

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1.4.11 Installation positions of bulbs for illumi‐

nating odometer display, multi-function
indicator (MFI)/digital clock and selector
lever display
1 - Bulb for selector lever display illumination
2 - Bulb for odometer display illumination
n AG. Volkswagen A ge G do
swa es n
3 - Bulb for MFI / digital clockbillumination
yV
olk ot g
ua
ed ran
oris tee
th or
au ac
ss

ce
le
un

pt
1.4.12 Removing and installing bulbs for illumi‐

an
d
itte

y li
nating odometer display, multi-function
erm

ab
ility
ot p

indicator (MFI)/digital clock and selector

wit
is n

lever display

h re
ole,

spec
urposes, in part or in wh

– Turn bulb holder until notch -1- is vertical (unlocked) and pull

t to the co
out bulb.
– Insert new bulb and turn bulb holder until notch -1- is horizontal
(locked).

rrectness o
cial p

f in
1.4.13 Components on printed circuit board

form
mer

front on vehicles with MFI

atio
om

n
c

1 - Printed circuit board i

or

n thi
te

sd
a

2 - Conductor strip for dash panel insert illumination

iv

o
pr

cum
r
fo

3 - Left/right turn signal warning lamps

en
ng

t.
yi Co
op
4 - Right warning lamps
C py
t. rig
gh ht
yri by
5 - Odometer display, do not renew separately cop Vo
by lksw
cted agen
Prote AG.
6 - Left warning lamps
7 - Multi-function indicator (MFI), do not renew separately

1.4.14 Components on printed circuit board

back on vehicles with MFI
1 - Voltage stabiliser, do not renew separately
2 - Oil pressure warning buzzer
3 - Conductor strip for dash panel insert illumination
4 - Connector for conductor strip
5 - 28-pin connector for dash panel insert wiring harness

1. Dash panel insert ▸ 12.95 137

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1.4.15 Removing and installing multi-function

display pressure sender -G55-
– Loosen cross-head bolts -3-.
AG. Volkswagen AG d
agen oes
– Pull pressure sender off dash panel insert. Volksw not
gu
by ara
d
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

1.4.16 Removing speedometer drive shaft from

h re
hole

spec
dash panel
es, in part or in w

t to the co
Note

rrectness of i
The drive shaft is split in the engine compartment and locked on
l purpos

the dash panel insert.

nform
ercia

– Release plastic coupling of drive shaft at dash panel insert by

compressing the side web and pull off drive shaft from hous‐
m

at
ing.
om

ion
c

in t
r

– Unscrew coupling -1- from drive shaft and pull out drive shaft
o

his
te

with rubber gasket -2- through opening in partition to passen‐

a

do
riv

ger compartment.
p

cum
for

en
ng

t.
yi Co
1.4.17 Checking LED Cop py
t. rig
gh ht
pyri by
The negative terminal is marked by:
co Vo
by lksw
cted agen
Prote AG.
1 - Phase on diode housing
2 - Larger terminal in diode housing
With some diodes the negative terminal connection is also offset.

– At hand multimeter -V.A.G 1526 B- simultaneously press but‐

tons for resistance and voltage measurement -arrows-.
– Connect red terminal “+” to LED (+).
– Connect black terminal “-” to LED (-).
LED must light up.

138 Rep. Gr.90 - Gauges, instruments

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1.4.18 Installing speed sender (at dash panel

insert) -G54-
AG. Volkswagen AG d
agen oes
olksw not
Caution d byV gu
ara
ise nte
or eo
th
To disconnect and connect the battery,
s au the procedure descri‐ ra
c
bed in the workshop manual should be strictly adhered to s

ce
le
⇒ page 29 .

un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

Note

h re
hole

spec
Speed sender signals are required for speed-dependent systems
es, in part or in w

t to the co
in the vehicle. On vehicles with mechanical speedometer the
sender is bolted onto back of the instrument and supplies 7 pulses
per wheel revolution. Inductive senders (2-pin) or Hall sender (3-

rrectness of i
pin) are used for radio with Gala 1994 ▸.
l purpos

– Carefully break out part -A- at perforated separating line on

back of dash panel insert.

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Insert speed sender in the recess created -1- and screw firmly
with cross-head bolts -3-.

– Make sure that conductor strip -3- lies without folds on sender
spring contact.

1. Dash panel insert ▸ 12.95 139

 n AG. Volkswagen AG do
Transporter 1991 ➤ , Transporter 1996 ➤ lkswage es n
o ot g
Electrical system - Edition 10.2004 byV ua
d ran
ir se tee
tho
u or
– Secure contact plate -A- with bolts -B-. ss
a ac

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos
1.4.19 Checking voltages, LEDs and bulbs with
test box (basic unit) -V.A.G 1598/14- .

nform
ercia

Special tools and workshop equipment required

m

at
om

ion
c

♦ Test box with 9 adapters -V.A.G 1598/A-

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Adapter cable -V.A.G 1598/13-

♦ Voltage tester -V.A.G 1527 B-

♦ Hand multimeter -V.A.G 1526 B-

140 Rep. Gr.90 - Gauges, instruments

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Note
AG. Volkswagen AG d
agen oes
lksw not
The bush markings don by the test box (basic unit) -V.A.G guar
o
♦ V
1598/14- are identical
ris
e
with the contact markings on the dash an
tee
ho
panel insert. aut or
ac
ss
♦ If the specification is attained, check conductor strip with con‐

ce
le
un

pt
nectors and components.

an
d
itte

y li
erm

♦ In case of deviation from specification, check wiring harness

ab
ility
according to current flow diagram. ⇒ Current flow diagrams,
ot p

wit
Electrical fault finding and Fitting locations
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
Note

Replace the dash panel wiring harness if it is found to be defective

rrectne
when the line positions are checked. The dash panel wiring har‐
ness must not be repaired.

ss o
cial p

f
Test prerequisites:

inform
mer

♦ Battery voltage OK.

atio
om

♦ Affected fuses OK.⇒ Current flow diagrams, Electrical fault

n
c

i
or

n
finding and Fitting locations

thi
te

sd
va

1 - Dash panel insert

i

o
pr

cum
r
fo

en
ng

2 - Test box (basic unit) -V.A.G 1598/14- with connecting cable

t.
yi Co
-3- t. Cop py
rig
gh ht
yri
4 - Hand multimeter -V.A.G 1526 B- p by
o Vo
by c lksw
cted agen
5 - Adapter line -V.A.G 1598/8- Prote AG.

6 - Dash panel insert wiring harness

– Fold down cover in front of relay plate.
– Disconnect multi-pin connector behind dash panel insert -1-.
– Connect test box (basic unit) -V.A.G 1598/14- with adapter line
-V.A.G 1598/13- to dash panel insert and disconnected wiring
harness (plug must audibly engage).
Test table:

– Measuring range: Switch on voltage measurement -V-.

Test Bushes - The voltage supply is tes‐ • Test conditions Specifications
step V.A.G 159 ted
8- – Additional operations
1 11 + 3 Terminal 30/terminal 31 • Ignition switched off Approx. battery voltage

1. Dash panel insert ▸ 12.95 141

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Measuring range: Switch on voltage measurement -V-.

Test Bushes - The voltage supply is tes‐ • Test conditions Specifications
step V.A.G 159 ted
8- – Additional operations
2 13 + 3 Terminal 15/terminal 31 – Switch on ignition. Approx. battery voltage
3 4) 22 + 3 Left turn signal warning • Ignition switched on Test lamp flashes
lamp
– Connect test lamp.

– Switch on left turn signal.

4 4) 24 + 3 Right turn signal warning • Ignition switched on Test lamp flashes
lamp
– Connect test lamp.

– Switch on right turn sig‐

nal.
5 12 + 3 Illumination for dash pan‐ • Ignition .switched on Approx. 2.5 V to battery volt‐
el insert and digital dis‐ AG Volkswagen AG d
agen oes age, depending on position of
play yV
–l Switch on light switch.
o ksw nocontroller
tg E 20
b ua
ed ra
6 25 + 3 Main beam warning
tho
rilamp
s
• Ignition switched on Approx.
nte
e battery voltage
or
au ac
ss – Switch on high beam.

ce
le
un

7 18 + 3 Dual circuit and hand‐ • Ignition switched on Approx. battery voltage

pt
an
d

brake system warning approx. 0 V

itte

y li
– Apply handbrake.
rm

lamp approx. battery voltage

ab
pe

ility
ot

– Release handbrake.

wit
, is n

h re
8 16 + 3 Alternator warning lamp • Ignition switched on Approx. 0 V
hole

spec
approx. battery voltage
es, in part or in w

– Start engine.

t to the co
9 5) 13 + 20 Glow period indicator • Engine cold (below glow Approx. battery voltage until
lamp temperature) glow temperature is attained

rrectness of i
– Switch on ignition.
l purpos

nform

4) Use test lamp -V.A.G 1527-

ercia

5) Not possible with hot engine

m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

142 Rep. Gr.90 - Gauges, instruments

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1.5 Pin assignment of connections on dash

panel insert
28-pin connector
1 - Ambient temperature sensor, earth 6)
2 - to coolant shortage indicator sender
3 - Terminal 31, earth
4 - MFI save switch (reset) 6)
5 - Terminal 31, earth 6)
6 - MFI save switch (memory) 6)
7 - Signal from speedometer at dash panel insert -G54- or from
electronic speedometer -G21-
8 - Oil pressure switch 0.9 bar / 1.4 bar / 1.8 bar
9 - Oil pressure switch 0.3 bar
10 - Terminal 1 / terminal W or speed signal from Digifant engine
control unit
11 - Terminal 30, battery positive
12 - Terminal 58b, illumination
13 - Terminal 15
14 - Rear fog light agen
AG. Volkswagen AG d
oes
olksw not
V gu
15 - MFI call-up button ed by (mode) 6) ara
nte
ris
o eo
16 - Alternator aut warning lamp, terminal 61
h
ra
ss c
6) Only with multi-function indicator
ce
le
un

pt
an
d

17 - Oil temperature sender 1)

itte

y li
erm

ab

18 - Dual circuit and handbrake system warning lamp / seat belt

ility
ot p

warning system warning lamp

wit
is n

h re
ole,

19 - Ambient temperature sensor, signal1)

spec
urposes, in part or in wh

20 - Glow period warning lamp

t to the co

21 - Fuel gauge
22 - Left turn signal warning lamp
rrectne

23 - Coolant temperature gauge

ss o

24 - Right turn signal warning lamp

cial p

f inform

25 - Main beam warning lamp

mer

atio
m

26 - Consumption signal from Digifant control unit, as of 01.93 1)

o

n
c

i
or

n thi

27 - Speed signal from speedometer sender (G 22)

te

sd
iva

o
r

28 - Selector lever display, as of 08.92

p

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Dash panel insert ▸ 12.95 143

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Only with multi-function indicator

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

144 Rep. Gr.90 - Gauges, instruments

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

2 Dash panel insert 01.96 ▸07.98

2.1 Removing and installing dash panel in‐

sert

Caution

To disconnect and connect the battery, the procedure descri‐

bed in the workshop manual should be strictly adhered to
⇒ page 29 .

Note

♦ The dash panel insert must not be dismantled.

♦ Fault finding programmes for specific systems and current cir‐
cuits ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
AG. Volkswagen AG d
agen oes
olksw not
Remove steering wheel: d by
V gu
ara
ise nte
or eo
h
aut ra
s c
Note s

ce
le
un

pt
an
d

Vehicles with driver side airbag ⇒ General body repairs, interior;

itte

y li
erm

Rep. Gr. 69 ; Airbag .

ab
ility
ot p

wit
is n

– Unclip cover cap -1-.

h re
ole,

spec
– Unscrew hexagon nut -2- (70 Nm).
urposes, in part or in wh

t to the co
– Mark steering wheel position and remove steering wheel -3-.
Remove steering column switch and trim:

rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2. Dash panel insert 01.96 ▸07.98 145

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Unscrew cross-head screws -1- and remove trim -2-.

n AG. Volkswagen AG do
– Pull off connectors at steering
olkscolumn
wage switch -4-. es n
o
yV t gu
b a
– Unscrew cross-head screws
ris
ed -5- and pull off steering column rante
switch-4-. utho eo
r a ac
ss
– Remove trim -3-.

ce
e
nl

pt
du

an
Remove complete dash panel insert:
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

– Unscrew two panel screws -1- and remove dash panel insert
cover -2- from spring clips -3-.
m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Unscrew left and right securing bolts -1-.

– Fold dash panel insert out forwards.
– Disconnect multi-pin connectors on back of dash panel insert.
– Take out dash panel insert.
Installing:
Installation is carried out in the reverse sequence.

146 Rep. Gr.90 - Gauges, instruments

 Transporter 1991 ➤ , Transporter 1996 ➤
AG. VolkswagElectrical
en AG
does system - Edition
10.2004
agen
olksw not
y V gu
db
2.2 Pin assignment of connections on dash
ara
ise nte
or eo
h
panel insert ss aut ra
c

ce
le
28-pin connector 1, black

un

pt
an
d
itte

y li
1 - Ambient temperature sensor, earth 7)

erm

ab
ility
ot p
2 - Coolant shortage indicator

wit
is n

h re
3 - Terminal 31, earth ole,

spec
urposes, in part or in wh

4 - MFI save switch (reset) 7)

t to the co
5 - Terminal 31 b, electronics earth
6 - MFI save switch (memory) 7)

rrectne
7 - Speed signal output

ss
8 - Oil pressure switch 1.8 bar

o
cial p

f in
9 - Oil pressure switch 0.3 bar

form
mer

10 - Terminal 1/terminal W

atio
om

n
c

11 - Terminal 30, battery positive

i
or

n thi
te

sd
a

12 - Terminal 58b, illumination

iv

o
pr

cum
r
fo

13 - Terminal 15

en
ng

t.
yi Co
op
14 - Rear fog light
C py
ht. rig
rig ht
py by
15 - MFI call-up button (mode) 7) co Vo
by lksw
cted agen
Prote
16 - Alternator warning lamp, terminal 61
AG.

17 - Oil temperature sender 7)

18 - Dual circuit and handbrake system warning lamp
19 - Ambient temperature sensor, signal7)
20 - Glow period warning lamp / CAT / check
21 - Fuel gauge
22 - Left turn signal warning lamp
23 - Coolant temperature gauge
24 - Right turn signal warning lamp
25 - Main beam warning lamp
26 - Fuel consumption input signal7)
27 - Speed signal from speedometer sender (Hall sender, at gear
box) -G22-
28 - Selector lever display AG 4
7) Only with multi-function indicator

2. Dash panel insert 01.96 ▸07.98 147

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

28-pin connector 2, red

1 - 25 vacant
26 - Fault warning lamp for TDI self-diagnosis (USA only)
27 - 28 vacant

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

148 Rep. Gr.90 - Gauges, instruments

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

3 Dash panel insert 08.98 ▸

Note

♦ The dash panel insert is available in different versions de‐

pending on the vehicle equipment level:
♦ Lowline version with rev counter and digital clock or
♦ Midline version with rev counter and multi-function indicator
(MFI as LCD in rev counter or as display unit in middle display
field of dash panel insert) or
♦ Highline version with rev counter, multi-function indicator and
navigation display unit.

3.1 Warning with oil level too low

Vehicles with LongLife Service are equipped with a dash panel
insert which informs the driver of a low oil level by means of an
acoustic signal and the illumination of a warning lamp.
AG. Volkswagen
When an oil level warning
lksw has been issued, the
agen AG do
eswarning
not can only
be reset by opening
db
y V the bonnet (actuation of the bonnet
o gu
a switch).
e ran
ris tee
3.2 au Fault detection and fault display
tho or
ac
ss
The dash panel insert is equipped with self-diagnosis, which
ce
e
nl

pt
du

makes fault finding easier.

an
itte

y li
erm

ab

1 - If the control unit detects a non-correctable fault in the dash

ility
ot p

panel insert data memory regarding

wit
, is n

h re

♦ the trip distance

hole

spec

♦ the trip count (k-number)

es, in part or in w

t to the co

♦ or the calibration of the speedometer

then “dEF” appears in the trip recorder display.
rrectness of i

– Renew dash panel insert ⇒ page 150 .

l purpos

2 - If the dash panel insert control unit detects a fault and nothing
is shown in the trip recorder display,
nf
ercia

perform the following operations before removing the dash panel

rm
m

atio

insert:
om

n in
c

Vehicles with dash panel insert without data BUS connection:

or

thi
te

sd
iva

– Read the fault memory of the dash panel insert using fault
o
r
rp

cu

reader -V.A.G 1551- ⇒ Electrical system, self-diagnosis; Rep.

o

m
f

en
ng

Gr. 01 ; Self-diagnosis of the dash panel insert with no data

t.
yi Co
bus connection; Performing self-diagnosis; Interrogating fault
Cop py
t. rig
memory . opyri
gh by
Vo
ht
c lksw
Vehicles with dash panel insert with data BUS connection:
by
cted agen
Prote AG.

– Read the fault memory of the dash panel insert using fault
reader -V.A.G 1551- ⇒ Electrical system, self-diagnosis; Rep.
Gr. 01 ; Self-diagnosis of the dash panel insert with data bus
connection; Performing self-diagnosis; Interrogating fault
memory .
Vehicles with dash panel insert without data BUS connection:
– Read service interval display values and distance recorder
with fault reader -V.A.G 1551- and note the values ⇒ Electrical
system, self-diagnosis; Rep. Gr. 01 ; Self-diagnosis of the
dash panel insert with no data bus connection .

3. Dash panel insert 08.98 ▸ 149

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Vehicles with dash panel insert with data BUS connection:

– Read service interval display values and distance recorder
with fault reader -V.A.G 1551- and note the values ⇒ Electrical
system, self-diagnosis; Rep. Gr. 01 ; Self-diagnosis of the
dash panel insert with data bus connection .
Continuation for all vehicles:
If the fault dictates that the dash panel insert requires replacement
the noted figures can be entered in the new dash panel insert.

3.3 Removing and installing dash panel in‐

sert

Caution

To disconnect and connect the battery, the procedure descri‐

bed in the workshop manual should be strictlyagadhered
en AG. V to agen AG doe
olksw
⇒ page 29 . Volksw s no
tg y ua
db ran
rise tee
tho or
s au ac
s

ce
e

Note
nl

pt
du

an
itte

y li
Observe the notes and work procedure instructions for fault rec‐
erm

ab
ility
ognition and fault displays before removing the dash panel insert
ot p

⇒ page 149 .

wit
, is n

h re
hole

spec
3.3.1 Removing steering wheel
es, in part or in w

t to the co
Note

rrectness of i
Vehicles with driver side airbag ⇒ General body repairs, interior;
l purpos

Rep. Gr. 69 ; Airbag . nf

ercia

– Unclip cover cap -1-.

orm
m

atio

– Unscrew hexagon nut -2- (67 Nm).

om

n in
or c

– Mark steering wheel position and remove steering wheel -3-.

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

150 Rep. Gr.90 - Gauges, instruments

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

3.3.2 Removing steering column switch and

trim
– Unscrew cross-head screws -1- and detach trim -2- from
catch.

Note

The self-diagnosis connecting bush is engaged in the lower trim.

Removal of the connecting bush is necessary only if the footwell
trim disturbs further work.

– Pull off connectors at steering column switch -4-.

– Unscrew cross-head screws -5- and pull off steering column
switch-4-.
– Remove trim -3-.

3.3.3 Removing dash panel insert

– Unscrew two panel screws -1- and remove dash panel insert
cover -2- from spring clips -3-.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
– Unscrew left and right securing bolts -1-.
ce
e
nl

pt
du

an

– Fold dash panel insert out forwards.

itte

y li
erm

ab

– Disconnect multi-pin connectors on back of dash panel insert.

ility
ot p

wit

– Take out dash panel insert.

, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

3.3.4 Installing dash panel insert

nform
ercia

– Insert dash panel insert into dash panel insert aperture and
m

at

reconnect connections.
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
151
Prote AG.
3. Dash panel insert 08.98 ▸
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Secure wiring harness for blue multi-pin connector (32-pin) to

back of dash panel insert using clamp - arrow.
– Perform remainder of installation in opposite sequence to re‐
moval sequence.
– After completing installation, check function of dash panel in‐
sert.
If the dash panel insert has been replaced because it was defec‐
tive and a functional check does not display a fault then the
following work must be completed afterwards:
Vehicles with dash panel insert without data BUS connection:
– Code dash panel insert ⇒ Electrical
n AG. Vosystem, self-diagnosis;
lkswagen AG do
wage
Rep. Gr. 01 ; Self-diagnosis
Volks of the dash panel insert es n
owith
t gu no
y
data bus connection
se
d.b ara
n ri te
ho e
– Adapt odometeraut display ⇒ Electrical system, self-diagnosis; or a
c
Rep. Gr. 01 ; Self-diagnosis of the dash panel insert with no
ss

ce
le

data bus connection .

un

pt
an
d
itte

y li
– Adapt service interval data ⇒ Electrical system, self-diagno‐
erm

ab
sis; Rep. Gr. 01 ; Self-diagnosis of the dash panel insert with

ility
ot p

no data bus connection .

wit
is n

h re
Vehicles with dash panel insert with data BUS connection:
ole,

spec
urposes, in part or in wh

– Code dash panel insert ⇒ Electrical system, self-diagnosis;

t to the co
Rep. Gr. 01 ; Self-diagnosis of the dash panel insert with data
bus connection .
– Coding diagnostic interface for data bus, only for dash panel rrectne
inserts with data BUS connection ⇒ Electrical system, self-
diagnosis; Rep. Gr. 01 ; Self-diagnosis of the dash panel insert
ss

with data bus connection

o
cial p

f in

– Adapt odometer display ⇒ Electrical system, self-diagnosis;

form
mer

Rep. Gr. 01 ; Self-diagnosis of the dash panel insert with data

atio

bus connection .
om

n
c

i
or

– Adapt service interval data ⇒ Electrical system, self-diagno‐

thi
te

sis; Rep. Gr. 01 ; Self-diagnosis of the dash panel insert with

sd
iva

o
r

data bus connection .

p

cum
r
fo

en
ng

Continuation for all vehicles:

t.
yi Co
Cop py
.
If a dash panel insert with the function Convenience anti-theft
t rig
gh ht
yri by
system is replaced, then for vehicles with cop Vo
by lksw
cted agen
Prote
♦ Radio system BETA 08.98 ▸
AG.

♦ Radio system GAMMA 08.98 ▸

♦ Radio navigation system
the electronic anti-theft system of the radio needs to be reactiva‐
ted ⇒ Communication; Rep. Gr. 91 .
The convenience anti-theft system is operative after first activa‐
tion of electronic anti-theft system.
Operating notes on the convenience anti-theft system ⇒ Com‐
munication; Rep. Gr. 91 .

152 Rep. Gr.90 - Gauges, instruments

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004
n AG. Volkswagen AG do
kswage es n
3.4 Dash panel insert, rear view ol ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
Note

ce
e
nl

pt
du

an
itte

♦ The dash panel insert must not be dismantled.

y li
erm

ab
ility
♦ Perform self-diagnosis for fault finding ⇒ Electrical system,
ot p

self-diagnosis; Rep. Gr. 01 .

wit
, is n

h re
hole

♦ Fault finding programmes for specific systems and current cir‐

spec
cuits ⇒ Current flow diagrams, Electrical fault finding and
es, in part or in w

t to the co
Fitting locations.

rrectness of i
1 - 32-pin connector
l purpos

❑ Green
❑ Additional features

nform
ercia

❑ Pin assignment on dash

panel inserts without da‐
m

at
om

ta BUS connection

ion
c

⇒ page 156

in t
or

his
e

❑ Pin assignment on dash

at

do
riv

panel inserts with data

p

cum
or

BUS connection
f

en
ng

t.
⇒ page 158
yi Co
Cop py
t. rig
2 - 20-pin connector
gh ht
pyri by
Vo
co
❑ Red.
by lksw
cted agen
Prote AG.
❑ Highline version
❑ Pin assignment on dash
panel inserts without da‐
ta BUS connection
⇒ page 156
❑ Pin assignment on dash
panel inserts with data
BUS connection
⇒ page 158
3 - Clamp for securing wiring
harness
4 - Warning buzzer/gong
❑ Oil pressure warning
❑ Oil level warning (on ve‐
hicles with LongLife
Service)
❑ Lights switched on
warning
❑ Brake system fault
❑ Brake pad wear warning
❑ Ignition key warning
(certain countries only)
❑ Seat belt warning (only certain countries)
❑ Speed warning (only certain countries)
5 - 32-pin connector
❑ Blue
❑ Basic functions
❑ Pin assignment on dash panel inserts without data BUS connection ⇒ page 155
❑ Pin assignment on dash panel inserts with data BUS connection ⇒ page 157

3. Dash panel insert 08.98 ▸ 153

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

3.5 Pin assignment of connections on dash

panel insert with no data BUS connec‐
tion

Note

The pin assignment on the dash panel insert depends on the ve‐
hicle's equipment and the country version and engine type of the
vehicle.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

154 Rep. Gr.90 - Gauges, instruments

 AG. Volkswagen AG d
agen oes
olksw not
y V gu
rise
d b
Transporter 1991 ➤ ara, Transporter 1996 ➤
nte
autho
Electrical system e o - Edition 10.2004
ra
ss c

ce
le
3.5.1 32-pin connector, blue

un

pt
an
d
itte

y li
1 - Terminal 15, positive

rm

ab
pe

ility
2 - Right turn signal warning lamp

ot

wit
, is n

h re
3 - Output signal 1 from electronic speedometer

hole

spec
4 - Trailer operation warning lamp es, in part or in w

t to the co
5 - Fuel gauge
6 - Airbag (connector connected to earth on vehicles without air‐

rrectness of i
bag)
l purpos

7 - Terminal 31, sender earth

8 - Coolant temperature gauge

nform
ercia

9 - Terminal 31, earth

m

a
com

tio
10 - Oil pressure switch

n in
r
te o

thi
11 - RPM signal

s
iva

do
r
rp

cum
12 - Alternator warning lamp, terminal 61
fo

en
ng

t.
yi Co
13 - Glow period warning lamp (diesel engine only) or fault warn‐ Cop py
ing lamp for electrical accelerator
t. rig
gh ht
pyri by
Vo
o
14 - Rear fog light warning lamp
c by lksw
cted agen
Prote AG.
15 - 16: vacant
17 - Main beam warning lamp, terminal 56a
18 - Left turn signal warning lamp
19 - Anti-lock brake system (connected to earth on vehicles with‐
out ABS)
20 - Dash panel insert illumination, terminal 58b
21 - Signal for driver door open
22 - Coolant shortage indicator
23 - Terminal 30, positive
24 - Terminal 31, earth
25 - Self-diagnosis/K cable
26 - Parking light right, signal for lights on warning buzzer
27 - Parking light left, signal for lights on warning buzzer
28 - Input signal to electronic speedometer
29 - Brake system warning lamp
30 - S-contact
31 - Seat belt warning system
32 - Exhaust gas warning lamp

3. Dash panel insert 08.98 ▸ 155

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

3.5.2 32-pin connector, green lksw

agen
AG. Volkswagen AG d
oes
not
Vo gu
y
1 - 6: vacant rise
d b ara
nte
tho eo
7 - Brake pad wear s au ra
c
s

ce
e
8 - 9: vacant

nl

pt
du

an
itte
10 - Fuel reserve warning

y li
erm

ab
ility
11 - 12: vacant
ot p

wit
, is n

13 - Handbrake warning lamp

h re
hole

spec
14 - 22: vacant
es, in part or in w

t to the co
23 - MFI save switch (memory)
24 - MFI call-up button (mode)

rrectness of i
25 - MFI save switch (reset)
l purpos

26 - Ambient temperature sensor

27 - 30: vacant

nform
ercia

31 - Selector lever display

m

at
om

ion
32 - Fuel consumption signal
c

in t
or

his
ate

do
riv

3.5.3 20-pin connector, red

p

cum
for

en
ng

t.
yi
1 - 11: vacant
Co
Cop py
t. rig
12 - Radio/navigation - clock
gh ht
pyri by
Vo
co lksw
by
13 - Radio/navigation - data cted agen
Prote AG.

14 - Not assigned
15 - Radio/navigation - enable
16 - 20: vacant

3.6 Pin assignment of connections at dash

panel insert with data BUS connection
Dash panel inserts with data BUS connection are being used as
of model year 2000 at first only in vehicles with LongLife Service
(PR. no. QG1).

Note

The pin assignment on the dash panel insert depends on the ve‐
hicle's equipment and the country version and engine type of the
vehicle.

156 Rep. Gr.90 - Gauges, instruments

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

3.6.1 32-pin connector, blue

1 - Terminal 15, positive
2 - Right turn signal warning lamp
3 - Output signal 1 from electronic speedometer
4 - Trailer operation warning lamp
5 - Fuel gauge
6 - Airbag (connector connected to earth on vehicles without air‐
bag)
7 - Terminal 31, sender earth
8 - Coolant temperature gauge
9 - Terminal 31, earth
10 - Oil pressure switch
11 - RPM signal
12 - Alternator warning lamp, terminal 61
13 - Glow period warning lamp
agen
AG. V(diesel
olkswageengine
n AG d only) or fault warn‐
oes
ing lamp for electrical
V olkswaccelerator not
g
by ua
ed ran
14 - Rear fog
ho
ris light warning lamp tee
t or
au ac
15 - 16:ssvacant
ce
le
un

17 - Main beam warning lamp, terminal 56a

pt
an
d
itte

y li

18 - Left turn signal warning lamp

erm

ab
ility
ot p

19 - Anti-lock brake system (connected to earth on vehicles with‐

wit
is n

out ABS)
h re
ole,

spec

20 - Dash panel insert illumination, terminal 58b

urposes, in part or in wh

t to the co

21 - Signal for driver door open

22 - Coolant shortage indicator
rrectne

23 - Terminal 30, positive

24 - Terminal 31, earth
ss o
cial p

25 - Self-diagnosis/K cable
inform
mer

26 - Parking light right, signal for lights on warning buzzer

atio
om

27 - Parking light left, signal for lights on warning buzzer

n
c

i
or

n thi
e

28 - Input signal to electronic speedometer

t

sd
iva

o
pr

cum

29 - Brake system warning lamp

r
fo

en
ng

t.
yi Co
30 - S-contact t. Cop py
rig
gh ht
31 - Seat belt warning system yri
p by
co Vo
by lksw
cted
32 - Exhaust gas warning lamp
agen
Prote AG.

3. Dash panel insert 08.98 ▸ 157

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

3.6.2 32-pin connector, green

1 - 6: vacant
7 - Brake pad wear
8 - 9: vacant
10 - Fuel reserve warning
11 - Signal for vehicle stationary agen
AG. Volkswagen AG d
oes
olksw not
12 - Not assigned ed byV gu
ara
ris nte
13 - Signal for handbrake
aut control
ho eo
ra
ss c
14 - Traction control system/vehicle stabilisation

ce
le
un

pt
an
d

15 - 17: vacant
itte

y li
rm

ab
18 - Oil temperature and level signal
pe

ility
ot

wit
, is n

19 - CAN data bus for drive, high input signal

h re
hole

20 - CAN data bus for drive, low input signal

spec
es, in part or in w

t to the co
21 - Not assigned
22 - Signal for bonnet open

rrectness of i
23 - MFI save switch (memory)
l purpos

24 - MFI call-up button (mode)

25 - MFI save switch (reset)

nform
ercia

26 - Ambient temperature sensor

m

a
com

tio

27 - 30: vacant
n in
r
te o

thi

31 - Selector lever display

s
iva

do
r
rp

32 - Fuel consumption signal

um
fo

en
ng

t.
yi Co
op
3.6.3 20-pin connector, red
C py
ht. rig
rig ht
py by
o Vo
1 - 11: vacant by c lksw
cted agen
Prote AG.
12 - Radio/navigation - clock
13 - Radio/navigation - data
14 - Not assigned
15 - Radio/navigation - enable
16 - 20: vacant

158 Rep. Gr.90 - Gauges, instruments

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

4 Service interval display

4.1 Function
The service interval display electronics is comprised of, amongst
other items: n AG. Volkswagen A ge G do
swa es n
♦ a time recorder
by
Vol
k ot g
ua
ed ran
and ris tee
tho or
au ac
♦ two
ss distance recorders.

ce
e
nl

pt
du

The electronics evaluates the recorders so that the customer is

an
itte

y li
informed
erm

ab
ility
ot p

♦ after a predetermined time period is exceeded

wit
, is n

h re
or
hole

spec
♦ after a predetermined distance is reached
es, in part or in w

t to the co
via the service interval display that a service is required (accord‐
ing to whichever occurs first).

rrectness of i
4.2 Service interval display on dash panel
l purpos

inserts with no data BUS connection

nf
ercia

or

4.2.1 Service interval display

m
m

atio
om

n in

Between services, only the total distance and distance travelled

or c

thi

(trip) is shown in the odometer display -2-.

te

sd
iva

o
r

When a service due date is reached, the type of service flashes

rp

cu
o

in the odometer display -2- after the ignition is switched on (Serv‐

f

en
ng

t.
yi
ice table ⇒ page 159 ).
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
Prote Note
cted AG.
agen

♦ The display can be switched back to trip recorder by pressing

key -1-.
♦ The display will return to trip recorder one minute after starting
the engine.

4.2.2 Service table

Indicated on dis‐ Remark: Type of service :
play:
Distance and Country code Engine oil change every
Service OEL or “D”other coun‐ 15,000 km
Service OIL tries
or:
Distance and All countries Inspection service every
service INSP 12 months or every
30,000 km
After a service is performed, the corresponding service type must
also be called and reset.
The service interval display can be reset using one of two meth‐
ods:

4. Service interval display 159

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Vehicles with dash panel insert with data BUS connection:

♦ with the fault reader -V.A.G 1551- ⇒ Electrical system, self-
diagnosis; Rep. Gr. 01 ; Self-diagnosis of the dash panel insert
with data bus connection; Resetting service interval display .
or, as described in the following,
♦ with trip recorder and clock buttons on dash panel insert
⇒ page 162
Vehicles with dash panel insert without data BUS connection: AG. Volkswagen AG d
agen oes
ksw
♦ with the fault reader -V.A.G 1551- ⇒ Electrical system, self- by V ol not
gu
ara
diagnosis; Rep. Gr. 01 ; Self-diagnosis of the dash panel insert
rised
nte
without data bus connection; Resetting service interval udis‐
tho eo
ra
play . ss a c

ce
e
nl
or, as described in the following,

pt
du

an
itte

y li
♦ with trip recorder and clock buttons on dash panel insert
erm

ab
⇒ page 160

ility
ot p

wit
, is n

4.2.3 Resetting service interval display on

h re
hole

spec
dash panel inserts without data BUS
es, in part or in w

connection

t to the co
rrectness of i
Note
l purpos

Each service must be called individually as only the distance re‐

corder and time counter of the actual service displayed can be

nform
ercia

reset.
m

at
om

i
Reset the display as follows:

on
c

in t
or

– Switch off ignition.

his
ate

do
priv

c
– Press button -1- next to speedometer and keep pressed.

um
for

en
ng

t.
– Switch on ignition and release button -1-.
yi Co
Cop py
ht. rig
The odometer display -2- shows the lettering Service OEL (with rig ht
py by
country code “D”) or Service OIL (other countries).
co Vo
by lksw
cted agen
Prote AG.

Note

♦ Pressing the trip recorder button -1- again switches the display
to INSP service without resetting the OEL (or OIL) service.
♦ Note that only the actual display shown can be reset.

– Turn adjusting knob -1- next to rev counter clockwise.

The service shown on the odometer display is reset and the dis‐
play shows: “service _ _ _”
– Switch off ignition.

160 Rep. Gr.90 - Gauges, instruments

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

4.3 Service interval display on dash panel

inserts with data BUS connection
Dash panel inserts with data BUS connection are being used as
of model year 2000 at first only in vehicles with LongLife Service
(PR. no. QG1).

4.3.1 Service interval display

Dash panel inserts with data BUS connection notify the driver of
a due service only by displaying “Service”.
Prewarning:
A prewarning for a due service first occurs 3000 km before the
end of the interval.
After the ignition is switched on the service due status is displayed
for 20 seconds.
Display in odometer display on Lowline version dash panel in‐
serts:
AG. Volkswagen AG d
agen oes
ksw
Service km 3000 by
Vol not
gu
d ara
ise nte
or eo
h
ut ra
Display in display unit in middle
ss a display zone on Midline and c
Highline version dash panel inserts:

ce
e
nl

pt
du

an
itte

y li
erm

ab
SERVICE in 3000

ility
ot p

km---------------

wit
, is n

PRND432

h re
hole

spec
es, in part or in w

The prewarning is subsequently updated by the actual distance

t to the co
in 100 km increments. The next time the ignition is switched on
(terminal 15 on) the service prewarning then appears with the
updated mileage, e.g.: rrectness of i
l purpos

SERVICE
in 2800 km
nform
ercia

---------------
PRND432
m

at
om

ion
c

in t
or

his
ate

do
riv

Note
p

cum
for

en
ng

t.
In dash panel inserts with mileage display the prewarning dis‐
yi Co
op
tance is set to 2000 miles.
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
Service request: cted agen
Prote AG.

After the prewarning expires the service request is displayed.

After the ignition is switched on the service due status is flashed
for 20 seconds.
Display in odometer display on Lowline version dash panel in‐
serts:

Service

Display in display unit in middle display zone on Midline and

Highline version dash panel inserts:

4. Service interval display 161

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

SERVICE
NOW
---------------
PRND432

The service interval display can be reset using one of two meth‐
ods:
♦ with the fault reader -V.A.G 1551- ⇒ Electrical system, self-
diagnosis; Rep. Gr. 01 ; Self-diagnosis of the dash panel insert
with data bus connection; Resetting service interval display .
or, as described in the following,
♦ With trip recorder and clock buttons on dash panel insert
⇒ page 162

Note
AG. Volkswagen AG d
agen oes
lksw not
♦ Resetting with the adjusting buttond bony V the dash panel insert
o gu
ara
sets the service interval to 15,000
oris km.
e nte
eo
h
ut ra
♦ Other service intervals cansbe
s set (adapted) only with the fault
a c
reader -V.A.G 1551- .

ce
le
un

pt
an
d

♦ Please also refer to the information on the flexible service in‐

itte

y li
terval display:
erm

ab
ility
ot p

wit
is n

⇒ Owner's manual

h re
ole,

spec
⇒ Maintenance ; Booklet 01
urposes, in part or in wh

t to the co
⇒ Electrical system self-diagnosis; Rep. Gr. 01

4.3.2 Resetting service interval display on rrectne

dash panel inserts with data BUS con‐
nection
ss o
cial p

Reset the display as follows:

inform
mer

– Switch off ignition.

atio
om

– Press button -1- next to speedometer and keep pressed.

n
c

i
or

n thi
e

– Switch on ignition and release button -1-.

t

sd
iva

o
pr

cum

The odometer display -2- in Lowline version dash panel inserts

r
fo

en
ng

displays “Service”.
t.
yi Co
Cop py
The display unit in the middle display field of Midline or Highline ht. rig
rig ht
version dash panel inserts shows “SERVICE NOW”.
py by
co Vo
by lksw
cted agen
Prote AG.

162 Rep. Gr.90 - Gauges, instruments

 AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
ut
ho eo
ra Transporter 1991 ➤ , Transporter 1996 ➤
a
ss c Electrical system - Edition 10.2004

ce
e
nl

pt
du

an
– Turn adjusting knob -1- next to rev counter clockwise.
itte

y li
erm

ab
The displayed service is reset and the display content is deleted.

ility
ot p

wit
– Switch off ignition.
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4. Service interval display 163

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

5 Tachograph ▸ 04.99

Note

♦ The tachograph hood and tachograph are not equipped with

self-diagnosis for fault finding.
♦ In case of electrical faults at tachograph hood or tachograph
proceed according to current flow diagram. ⇒ Current flow di‐
agrams, Electrical fault finding and Fitting locations
♦ The tachograph hood is not equipped with a service interval
display. Consult the service schedule on when a service is re‐
quired for the vehicle.
♦ Remove and install the tachograph hood analogously to the
dash panel insert ⇒ page 145 .
AG. Volkswagen AG d
agen oes
ksw
5.1 Pin assignment of the connections on ol not
byV gu
ara
ed
the tachograph hood ris nte
ho eo
aut ra
s c
5.1.1 28-pin connector 1, black
s

ce
le
un

pt
an
d
itte

1 - Not assigned

y li
rm

ab
pe

ility
2 - Coolant shortage indicator
ot

wit
, is n

3 - Terminal 31, earth

h re
hole

spec
4 - 7 vacant
es, in part or in w

t to the co
8 - Oil pressure switch 1.8 bar
9 - Not assigned

rrectness of i
10 - Terminal 1/terminal W
l purpos

11 - Not assigned
12 - Terminal 58b, illumination

nform
ercia

13 - Terminal 15
m

a
com

tio
14 - Rear fog light

n in
r
te o

15 - Not assigned thi

s
iva

do
r
rp

cum

16 - Alternator warning lamp, terminal 61

fo

en
ng

t.
yi Co
17 - Not assigned . Cop py
rig
ht ht
rig
18 - Brake system warning lamp py by
co Vo
by lksw
cted
19 - Not assigned
agen
Prote AG.

20 - Glow period warning lamp / CAT / check

21 - Fuel gauge
22 - Left turn signal warning lamp
23 - Coolant temperature gauge
24 - Right turn signal warning lamp
25 - Main beam warning lamp
26 - 28 vacant

164 Rep. Gr.90 - Gauges, instruments

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

5.2 Pin assignment of connections on ta‐

n AG. Volkswagen AG do
chograph olks
wage es n
ot
yV gu
db ara
rise nte
tho eo
Note au ra
c
ss

ce
le
un
The designations of the pin assignments are printed on the back

pt
an
d
of the tachograph.

itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
5.2.1 8-pin connector A
1 - Terminal 30, battery positive

rrectness of i
2 - Terminal 58, tachograph illumination
l purpos

3 - Terminal 15, fused

4 - Not assigned

nform
ercia

5 - Terminal 31, earth

m

a
com

tion in
6 - Terminal 31, earth
r
te o

thi
s
7 - 8 vacant
iva

do
r
rp

cum
fo

5.2.2 8-pin connector B

en
ng

t.
yi Co
op py
1 - Tachograph sender, positive t. C rig
gh ht
pyri by
2 - Tachograph sender, negative
o Vo
by c lksw
cted agen
Prote AG.
3 - Speed signal
4 - Speed signal, inverted
5 - 8 vacant

5.2.3 8-pin connector C

1 - 8 vacant

5.2.4 8-pin connector D

1 - Signal for auxiliary recording, tone sequence system
2 - Signal for auxiliary recording, rotating beacon
3 - Speed signal (4 pulses/revolution)
4 - 8 vacant

5. Tachograph ▸ 04.99 165

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004
AG. Volkswagen AG d
agen oes
6 Tachograph 05.00 ▸ d byV
olksw not
gu
ara
ise nte
or eo
h
aut ra
Note ss c

ce
e
nl

pt
du

an
♦ When handling complaints, it is essential to understand the

itte

y li
function and operation of the tachograph.

erm

ab
ility
ot p
♦ The tachograph hood and tachograph are not equipped with

wit
, is n
self-diagnosis for fault finding.

h re
hole

spec
♦ Additional information ⇒ Operating instructions

es, in part or in w

t to the co
♦ When retrofitting, repairing or fault finding ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations

rrectness of i
6.1 Pin assignment of connections on ta‐
l purpos

chograph

nf
ercia

orm
Note
m

atio
om

n in
or c

The designations of the pin assignments are printed on the back

thi
e

of the tachograph.
t

sd
iva

o
r
rp

cu
o

m
f

en
6.1.1 8-pin connector A, T8a
ng

t.
yi Co
Cop py
ht. rig
1 - Terminal 30, battery positive rig ht
py by
co Vo
by lksw
2 - Terminal 58, tachograph illumination Prote
cted AG.
agen

3 - Terminal 15, fused

4 - Data BUS line
5 - Terminal 31, earth
6 - Terminal 31, earth
7 - Not assigned
8 - Data BUS line

6.1.2 8-pin connector B, T8b

1 - Tachograph sender, positive
2 - Tachograph sender, negative
3 - Speed signal
4 - Speed signal, inverted
5 - 7 vacant
8 - Speedometer sender

166 Rep. Gr.90 - Gauges, instruments

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

6.1.3 8-pin connector CVolkswa

AG. gen AG
agen does
1 - 8 vacant olksw not
yV gu
db ara
rise nte
tho eo
s au ra
c
s

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
6.1.4 8-pin connector D
1 - 8 vacant

rrectness of i
6.2 Removing and installing tachograph
l purpos

Special tools and workshop equipment required

nf
ercia

♦ Release tool -T10104-

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

The tachograph release tool -T10104- is comprised of two iden‐

tical parts.
Removing:
– Insert release tool -T10104- in release slots and press down‐
wards -arrows- until tool engages.

6. Tachograph 05.00 ▸ 167

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Pull tachograph out of dash panel at handle lugs of release

tool, simultaneously pressing release tools downwards
-arrows-.

Note

When doing this the tachograph release tool -T10104- must not
be pushed to the side or tilted.

– To pull off the release tool -T10104- , press the tools upwards
-arrows- and simultaneously pull out.
Installing:
– Connect connectors to tachograph.
– Re-attach lead seal to connectors of tachograph n AG. Volkswagen AG do
lkswage es n
o ot g
– Slide tachograph level into the dash panel, until it snaps in the d byV ua
ran
assembly frame. orise
tee
th or
au ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

168 Rep. Gr.90 - Gauges, instruments

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

92 – Windscreen wash/wipe system

1 Windscreen wiper system

1.1 Assembly overview - windscreen wiper

system

Caution

To disconnect and connect the battery, the procedure descri‐

bed in the workshop manual should be strictly adhered to
⇒ page 29 . swa
gen AG
. Volkswagen AG
does
k not
Vol gu
d by ara
e nte
ris
utho eo
ra
a c
1 - Wiper blade ss

ce
le
un

❑ Adjusting park position

pt
an
d
itte

⇒ page 170 .

y li
rm

ab
❑ Removing and installing
pe

ility
rubber blade
ot

wit
, is n

⇒ page 171 .

h re
hole

spec
2 - Wiper arm
es, in part or in w

t to the co
3 - Cap
4 - M8 hexagon nut

rrectness of i
❑ 19 Nm
l purpos

5 - Washer
6 - Hexagon bolt M6

nform
ercia

❑ 5 Nm
m

a
com

t
7 - Rubber grommet

ion in
r
te o

8 - Spacer

thi
s
iva

do
r

9 - M8 hexagon nut
rp

cum
fo

en

❑ 25 Nm
ng

t.
yi Co
op py
10 - Connecting rod t. C rig
gh ht
pyri by
Vo
11 - M8 hexagon nut
co lksw
by
cted agen
Prote
❑ Self-locking
AG.

12 - Crank
❑ Setting park position
⇒ page 170
13 - Windscreen wiper motor -
V-
❑ Removing wiper frame

1. Windscreen wiper system 169

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

beforehand
14 - Toggle lever
15 - Spring washer
16 - Wiper frame
17 - O-ring
18 - Shim
19 - Washer
20 - Snap ring
21 - Plastic washer
22 - Spacer ring
23 - Hexagon nut M16 AG. Volkswagen AG d
agen oes
❑ 10 Nm olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
1.2 Setting park position ss c

ce
e
nl

pt
du

an
– Operate wiper motor and allow it to return to park position.
itte

y li
erm

ab
– Attach crank and align so that bottom edge is aligned with dril‐

ility
ot p

led hole -arrow-.

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

1.3 Adjusting wiper blade park position

rm
m

atio
m

– Set wiper blades at markings in windscreen.

o

n in
or c

thi
e

a - Marking for left-hand drive vehicles

t

sd
iva

o
r
rp

cu

b - Marking for right-hand drive vehicles

o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

170 Rep. Gr.92 - Windscreen wash/wipe system

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004
n AG. Volkswagen AG do
wage
1.4 Removing and installing wiper blade lks es n
o ot g
byV ua
rubber insert
d ran
ir se tee
tho
u or
a ac
– Using a pair of pliers press together both steel strips on the
ss

ce
e
enclosed side of the wiper rubber, slide sideways out of the

nl

pt
du
upper clip and remove rubber complete with strips from the

an
itte

y li
other clips of the wiper blades.

erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Fit new rubber insert into lower clips of wiper blade.

nf
ercia

– Guide both strips into the first groove of the rubber insert so

or
that the recesses in the strips face the rubber and engage in

m
m

atio
the rubber lugs of the groove.
om

n in
or c

– Using pliers press both steel strips and rubber together and

thi
e

insert in the upper clips so that the lugs of the clips on both
t

sd
iva

o
sides engage in the retaining slots -arrow- of the wiper blade
r
rp

cu
o

m
rubber.
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Windscreen wiper system 171

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004
AG. Volkswagen n AG do
wage es n
Volks ot g
by ua
2 Windscreen washer system (short ed ran
oris tee
th or
front end) ▸ 12.95 ss
au ac

ce
le
un

pt
an
d
itte

y li
erm

2.1 Assembly overview - windscreen washer system

ab
ility
ot p

wit
is n

h re
ole,

1 - Jets

spec
urposes, in part or in wh

❑ Removing ⇒ page 173 .

t to the co
❑ Adjusting ⇒ page 173 .
2 - Hose lock

rrectne
3 - Junction

s
4 - Hose

s o
cial p

f i
5 - Windscreen washer pump -

nform
V5-
mer

atio
❑ Connection
om

n
⇒ page 173 .
c

i
or

n thi
te

sd
6 - Seal
iva

o
pr

cum
r

7 - Plastic nut
fo

en
ng

t.
yi Co
8 - Reservoir Cop py
t. rig
gh
❑ Capacity 5 litres
ht
pyri by
Vo
co lksw
by
cted
9 - Reservoir cap
agen
Prote AG.

172 Rep. Gr.92 - Windscreen wash/wipe system

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

2.2 Removing and adjusting washer jets

2.2.1 Removing washer jets

– Loosen bolts and remove air inlet grid.
– Press washer jet catch to the side with screwdriver and re‐
move washer jet.

2.2.2 Adjusting washer spray jets

a - = 160 mm
b - = 320 mm agen
AG. Volkswagen AG d
oes
olksw not
V
c - = 400 mm ed by gu
ara
nte
ris
ho eo
aut ra
ss c
Note
ce
le
un

pt
an
d
itte

In vehicles with preadjusted washer jets (white dot under nozzle)

y li
erm

ab

check only jet adjustment. Adjustment not possible.

ility
ot p

wit
is n

h re
ole,

2.3 Hose connections at windscreen wash‐

spec
urposes, in part or in wh

er pump -V5-
t to the co

2.3.1 Connection of windscreen washer pump

-V5-
rrectne

A - Line to headlight washer system

ss o
cial p

B - Line to windscreen washer system

inform
mer

C - Line to rear window washer system

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2. Windscreen washer system (short front end) ▸ 12.95 173

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004
AG. Volkswagen AG d
agen oes
3 Windscreen washer system (long d byV
olksw not
gu
ara
front end) 01.96 ▸ ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
3.1 Assembly overview - windscreen washer system

an
d
itte

y li
rm

ab
pe

ility
ot
1 - Jets

wit
, is n

h re
❑ Removing ⇒ page 175 .
hole

spec
❑ Checking adjustment
es, in part or in w

t to the co
⇒ page 175
2 - Junction

rrectness of i
3 - Hose
l purpos

4 - Windscreen washer pump -

V5-

nform
ercia

❑ Connection
⇒ page 175 .
m

a
com

tio
5 - Seal

n in
r
te o

thi
6 - Reservoir

s
iva

do
r
rp

c
7 - Plastic nut

um
fo

en
ng

t.
yi
8 - Reservoir cap
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

174 Rep. Gr.92 - Windscreen wash/wipe system

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

3.2 Removing and adjusting washer jets

3.2.1 Removing washer jets

– Unclip trim under bonnet
– Loosen washer jet rubber seal -arrow- and pull washer jet
downwards out of catch.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

3.2.2 Checking washer jet adjustment

h re
hole

spec
es, in part or in w

t to the co
Note

♦ Check only washer jet settings. Adjustment not possible.

rrectness of i
♦ The fan spray of the washer jet must strike the upper third of
l purpos

the windscreen.

nform
ercia

3.3 Hose connections at windscreen wash‐

m

er pump -V5-

at
om

ion
c

in t
r

3.3.1 Connection of windscreen washer pump

o

his
ate

do
-V5-
priv

cum
for

en
g

A - Line to headlight washer system

n

t.
yi Co
Cop py
B - Line to windscreen washer system ht. rig
rig ht
py by
co Vo
C - Line to rear window washer system
by lksw
cted agen
Prote AG.

3. Windscreen washer system (long front end) 01.96 ▸ 175

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

4 Rear window wiper and washer sys‐

n AG. Volkswagen AG do
tem (tailgate)
Vol
ksw
age es n
ot g
y ua
db ran
rise tee
tho or
au
4.1 Assembly overview of rear window wipe/wash system
s c a
s

ce
e
nl

pt
du

an
itte

y li
1 - Wiper blade
erm

ab
ility
❑ Adjusting park position
ot p

wit
⇒ page 177 .
, is n

h re
❑ Removing and installing
hole

spec
rubber blade
es, in part or in w

⇒ page 171 .

t to the co
2 - Wiper arm

rrectness of i
3 - Spring washer
l purpos

4 - Toggle lever with linkage

5 - Connecting pipe for washer

nf
ercia

jet

orm
m

6 - Hose

atio
om

n in
c

7 - Rear window wiper motor -

or

thi
e

V12-
t

sd
iva

o
r

❑ Setting park position

rp

cu
o

⇒ page 177
f

en
ng

t.
yi Co
op
8 - Bracket for motor for rear
C py
t. rig
gh
window wiper -V12-
ht
pyri by
Vo
co lksw
by
9 - Rubber ring
cted agen
Prote AG.

10 - Spacer
11 - Hexagon bolt M6
❑ 5 Nm
12 - Hexagon bolt M6
❑ 5 Nm
13 - O-ring
14 - Shim
15 - Washer
16 - Snap ring
17 - Plastic washer
18 - Shim
19 - Hexagon nut M16
❑ 10 Nm
20 - Washer
21 - M8 hexagon nut
❑ 16 Nm
22 - Washer jet
23 - Cap

176 Rep. Gr.92 - Windscreen wash/wipe system

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

4.2 Setting park position

– Operate wiper motor and allow it to return to park position.
– Attach crank arm and align aso nthat top
AG. Volksedge
wagenis
AGaligned with
w ge does
drilled hole -arrow-. Volks not
g by ua
ed ran
oris tee
th or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
4.3 Adjusting rear window wiper park posi‐
tion

rrectness of i
l purpos

– Adjust wiper arm so that wiper blade is horizontal.

a - = 45 mm

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4.4 Adjusting washer spray jet

Centre of wiper field

4. Rear window wiper and washer system (tailgate) 177

 Transporter 1991 ➤ ge, nTransporter
AG. Volkswage1996
n AG d ➤
swa oes
Electrical system
y Volk - Edition 10.2004 not
gu
b ara
ed nte
oris e
th or
au
5 ss Rear window wiper and washer sys‐ac

ce
e

tem (rear hinged doors)

nl

pt
du

an
itte

y li
erm

ab
ility
ot p

5.1 Assembly overview of rear window

wit
, is n

h re
wipe/wash system
hole

spec
es, in part or in w

t to the co
Note

rrectness of i
The components for the left and right hinged doors are identical
⇒ page 180 and ⇒ page 180
l purpos

nf
ercia

1 - Wiper blade

orm
m

atio
❑ Adjusting park position
om

⇒ page 180 .

n in
or c

thi
❑ Removing and installing
te

sd
iva

rubber blade

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

178 Rep. Gr.92 - Windscreen wash/wipe system

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

⇒ page 171 .
2 - Wiper arm
3 - Washer jet
4 - Cap AG. Volkswagen AG d
agen oes
5 - M8 hexagon nut olksw not
y V gu
d b ara
❑ 16 Nm orise nte
eo
th
u ra
6 - Washer ss a c

ce
e
nl
7 - Hexagon nut M16

pt
du

an
itte

y li
❑ 10 Nm
erm

ab
ility
ot p

8 - Shim

wit
, is n

h re
9 - Plastic washer
hole

spec
10 - Circlip
es, in part or in w

t to the co
11 - Washer
12 - Shim

rrectness of i
13 - O-ring
l purpos

14 - Bracket for wiper shaft

15 - Spring washer

nf
ercia

orm
m

16 - Toggle lever

atio
om

n in
c

17 - Connecting pipe for wash‐

or

thi
er jet
te

sd
iva

o
r
rp

cu
18 - Hose
o

m
f

en
ng

t.
19 - Rubber grommet
yi Co
Cop py
t. rig
20 - Spacer
gh ht
pyri by
Vo
co lksw
by
21 - Rear window wiper motor -V12- Prote
cted AG.
agen

22 - Hexagon bolt M6
❑ 5 Nm
23 - Bracket for motor for rear window wiper -V12-
24 - Serrated washer
25 - Crank
❑ Setting park position ⇒ page 180
26 - Hexagon bolt M6
❑ 5 Nm
27 - M8 hexagon nut
❑ Self-locking
28 - Connecting rod

5. Rear window wiper and washer system (rear hinged doors) 179
 AG. Volkswagen AG d
Transporter 1991 ➤ , Transporter 1996 ➤ lksw
agen oes
not
o
Electrical system - Edition 10.2004 d by
V gu
ara
ise nte
or eo
th
Installation position of wiper motor for left rear hinged doors au ra
c
s

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne
Installation position of wiper motor for right rear hinged door

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

5.2 Setting park position

– Operate wiper motor and allow it to return to park position.
– Attach crank arm and align so that bottom edge is aligned with
drilled hole -arrow-.

5.3 Adjusting rear window wiper park posi‐

tion
– Adjust wiper arm so that the wiper blades are vertical.

180 Rep. Gr.92 - Windscreen wash/wipe system

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

5.4 Adjusting washer spray jet

a - = 150 mm
b - = 250 mm

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

5. Rear window wiper and washer system (rear hinged doors) 181
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004
AG. Volkswagen AG d
agen oes
6 Headlight washer system d by
Volksw not
gu
ara
ise nte
or eo
h
aut ra
s c
6.1 Assembly overview - headlight washer system
s

ce
e
nl

pt
du

an
itte

y li
erm

ab
1 - Reservoir cap

ility
ot p

wit
2 - Hexagon nut M6
, is n

h re
hole
3 - Pump for headlight washer

spec
system -V11-
es, in part or in w

t to the co
4 - Seal
5 - Hose clamp

rrectness of i
6 - T-piece
l purpos

❑ Note hose connections

7 - Hose 10 x 3

nf
ercia

orm
8 - Angled piece
m

atio
om

n in
9 - Hexagon bolt M6
or c

thi
te

sd
10 - Washer
iva

o
r
rp

cu
11 - Pop-up spray jet assembly
o

m
f

en
ng

t.
yi Co
12 - Rubber grommet Cop py
t. rig
gh ht
yri
13 - Jets p by
o Vo
by c lksw
cted
❑ Adjusting ⇒ page 185 .
agen
Prote AG.

14 - Headlight
15 - Reservoir
❑ Contents approx. 7 litres

6.2 Removing and installing spray jet as‐

sembly
Special tools and workshop equipment required

182 Rep. Gr.92 - Windscreen wash/wipe system

 AG. Volkswagen AG d
agen oes
olksw Transporter 1991not ➤ , Transporter 1996 ➤
byV gu
ara
rised
Electrical system
nte - Edition 10.2004
ho eo
aut ra
♦ Hose clamps up to Ø 40 mm -VAS
ss 3093- c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Removing:

nf
ercia

o
– With one of the hose clamps up to Ø 40 mm -VAS 3093- ,

rm
disconnect the headlight washer system hose at reservoir
m

atio
m

-arrow-.
o

n in
or c

thi
The figure shows the headlight removed for better understanding.
te

sd
iva

o
r
rp

– Pull out washer jet bracket against force of pop-up spray jet

cu
o

m
f

cylinder.

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Pull out washer jet bracket by cautiously giving small turns to

the right and left -arrow-.
Never tilt the washer jet bracket, as otherwise the guide tube of
the pop-up cylinder will break.
At the instant the washer jet bracket is pulled out, the pop-up cyl‐
inder guide tube springs back to its original position, ejecting a
considerable amount of washer concentrate. Protect yourself with
a suitable cloth or rag.
Installing:
– To install, insert washer jet bracket in pop-up cylinder up to
stop.
– Remove the hose clamps up to Ø 40 mm -VAS 3093- again.
– Adjusting spray jets ⇒ page 185 .

6.3 Removing and installing pop-up spray

jet cylinder
Special tools and workshop equipment required

6. Headlight washer system 183

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

♦ Hose clamps up to Ø 40 mm -VAS 3093-

Removing:
– With one of the hose clamps up to Ø 40 mm -VAS 3093- ,
disconnect the headlight washer system hose at reservoir
-arrow-.
The figure shows the headlight removed for better understanding.
– Removing both washer jet brackets ⇒ page 182 .
– Remove end panel under headlight ⇒ General body repairs,
exterior; Rep. Gr. 66 ; Trim.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
th
– Unscrew both securing bolts of pop-ups auspray jet cylinder ra
c
-arrows-. s

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Pull hose off pop-up cylinder -arrow-.

Installing:
nform
ercia

Install in reverse order of removal.

m

a
com

tio

– Remove the hose clamps up to Ø 40 mm -VAS 3093- again.

n in
r
te o

thi

– Adjusting spray jets ⇒ page 185 .

s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

184 Rep. Gr.92 - Windscreen wash/wipe system

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

6.4 Adjusting washer spray jets

– Pull out washer jets up to stop and fix in position with suitable
piece of wood. wage
n AG. Volkswagen AG do
es
olks not
Left headlight: yV gu
edb ara
ris nte
a - = 120 mm tho eo
au ra
c
ss
b - = 50 mm

ce
le
un

pt
an
d
Jet dimensions for the right headlight are a mirror image. itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

6. Headlight washer system 185

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

7 Hose repair
A new repair concept has been developed for repair work on wash
system hoses. Various connectors, special EPDM hoses and
heat-shrink hose are offered as replacement parts.

7.1 General description

♦ The replacement parts can be found in the electronic parts
catalogue (ETKA):
♦ Replacement parts are available for repair of both smooth and
corrugated pipes.

7.2 Repairing smooth pipe

Smooth pipe with a diameter or 5x1 mm or 6x1 mm can be re‐
paired with EPDM hose.
– Cut damaged section at right angles out of smooth pipe which
is to be repaired. n AG. Volkswagen A ge G do
swa es n
– Select the appropriate EPDM hose -2- and cable btiesy V accord‐
olk ot g
ua
ing to the electronic parts catalogue (ETKA). rised ran
tee
tho or
– Cut EPDM hose -2- so that ends -1- and s-3-
s a of smooth pipe
u ac
can each be pushed about 10 mm into the EPDM hose -2-.

ce
e
nl

pt
du

an
itte

y li
erm

ab
– Secure the repair joints with cable ties -1-.

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

7.3 Repairing corrugated pipe

ion
c

in t
or

his
e

Special tools and workshop equipment required

at

do
priv

♦ Hot air blower -VAS 5179- or

um
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Hot air blower -V.A.G 1416/- or

♦ Hot air blower -VAS 1978/14-

186 Rep. Gr.92 - Windscreen wash/wipe system

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Note

♦ Repair points must not be subjected to pulling or bending

forces.
♦ If the damaged section is longer than 20 mm, a new piece of
corrugated pipe must be used and the procedure described
below must be performed twice.

– Cut damaged section at right angles out of corrugated pipe

which is to be repaired.
– Select suitable end pieces -2- and -3- and correct sized shrink-
fit piping from the electronic parts catalogue (ETKA).
– Heat end of corrugated pipe -1-.
– Push connector -2- into corrugated pipe -2- -arrow A-.
– Heat end of corrugated pipe -4-.
– Push connector -3- into corrugated pipe -4- -arrow B-.

– Cut heat-shrink hose so that ends of corrugated pipe are each

covered by about 20 mm -dimension x-of heat-shrink hose.
n AG. Volkswagen AG do
– Push heat-shrink hose over corrugated pipe, olks
join
wageconnectors es n
ot g
and secure repair joints with heat-shrink
d b hose.
y V ua
ran
e
ris tee
tho or
au ac
ss

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

7. Hose repair 187

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

94 – Lights, bulbs, switches - exterior

1 Headlights (short front end) ▸ 12.95

1.1 Assembly overview - headlights

Caution

To disconnect and connect the battery, the procedure descri‐

bed in the workshop manual should be strictly adhered to
⇒ page 29 .

Note

After any measures which could affect the headlight setting, wthe
agen
AG. Volkswagen AG d
oes
headlights must be checked and if necessary adjusted y Vo lks not
gu
⇒ page 191 . ise
d b ara
n r tee
ho
aut or
ac
ss

ce
e

1 - Headlight unit
nl

pt
du

an
itte

❑ Removing and installing

y li
erm

ab
⇒ page 189 .

ility
ot p

❑ Adjusting headlights

wit
, is n

⇒ page 191 .

h re
hole

spec
2 - Left side light bulb -M1- and
es, in part or in w

right -M3-

t to the co
❑ Bulb 12 V, 4 W
❑ Removing and installing

rrectness of i
⇒ page 189 .
l purpos

3 - Left headlight twin filament

bulb/left headlight sealed
beam unit -L1- and right -L2- nform
ercia

❑ Halogen bulb H4 12 V,
m

at

60 W/55 W
om

ion
c

❑ Removing and installing

in t
or

his
e

⇒ page 189 .
at

do
priv

4 - Sealing cap
um
for

en
ng

t.
yi
5 - Left headlight range control
Co
op py
motor -V48- and right -V49- t. C rig
gh ht
yri by
❑ Only vehicles with head‐ cop Vo
by lksw
light range control cted agen
Prote AG.
❑ Removing and installing
⇒ page 190 .
6 - Control motor positioning
shaft
❑ Removing and installing
⇒ page 190 .
7 - Front left turn signal bulb -
M5- or front right -M7-
❑ Bulb 12 V, 21 W
❑ Removing and installing

188 Rep. Gr.94 - Lights, bulbs, switches - exterior

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

turn signal bulb

⇒ page 199 .
8 - Front turn signal lamp
❑ Removing ⇒ page 199 .

1.2 Renewing headlight bulbs

1.2.1 Removing and installing left headlight

twin filament bulb/left headlight sealed
beam unit -L1- or right -L2-
Removing:
– Pull connector off twin-filament bulb.
AG. Volkswagen AG d
– Remove sealing cap on back of headlight unit. agen oes
olksw not
V gu
by ara
– Release spring clamp -1- and swing downwards. rised
nte
ho eo
ut
– Pull bulb out of reflector. ss a ra
c

ce
e

Installing:
nl

pt
du

an
itte

y li
erm

ab
ility
Note
ot p

wit
, is n

h re
Do not touch bulb glass when fitting bulbs. Fingers leave traces
hole

spec
of grease on the bulb glass, which evaporate when the bulb is
es, in part or in w

switched on and cause the glass to cloud over.

t to the co
– Insert new bulb so that the lugs on the disc plate align with the
recesses in the reflector.

rrectness of i
– Check headlight settings and adjust if necessary
l purpos

⇒ page 191

nform
ercia

1.2.2 Removing and installing left side light

m

at
bulb -M1- or right side light bulb -M3-
om

ion
c

in t
or

Removing:
his
ate

do
priv

c
– Unscrew bulb with holder on connector from reflector.
um
for

en
ng

t.
Installing:
yi Co
Cop py
t. rig
– After changing bulb, screw holder with bulb into reflector.
gh ht
pyri by
Vo
o
by c lksw
– Check functioning of headlight after installing a new bulb. Prote
cted AG.
agen

– Check headlight settings and adjust if necessary

⇒ page 191

1.3 Removing and installing headlight insert

Note

Headlight must be adjusted after any measures which could affect

the headlight setting

Removing:
– Remove end plate under headlight ⇒ Body Repairs; Rep. Gr.
50

1. Headlights (short front end) ▸ 12.95 189

 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Transporter 1991 ➤ , Transporter
auth 1996 ➤ or
ac
Electrical system - Edition 10.2004 ss

ce
le
un

pt
an
d
– Unscrew securing bolts -arrows- and pull out headlight unit

itte

y li
forwards.

erm

ab
ility
ot p
– Disconnect headlight and turn signal multi-pin connectors.

wit
is n

h re
ole,
Installing:

spec
urposes, in part or in wh
Installation is carried out in the reverse sequence of removal.

t to the co
– Check headlight settings and adjust if necessary
⇒ page 191

rrectness o
cial p

f inform
1.4 Removing and installing left headlight
mer

atio
m

range control motor -V48- and right

o

n
c

i
or

n
headlight range control motor -V49-

thi
te

sd
iva

o
pr

cum
r
fo

en
ng

Note
t.
yi Co
Cop py
t. rig
♦ The control motor can only be removed and installed when the
gh ht
pyri by
headlight housing has been removed.
co Vo
by lksw
cted agen
Prote AG.
♦ If control motors are removed and installed or renewed, al‐
ways carry out the headlight basic setting with a beam setting
appliance (inclination: see sticker or embossing on left hand
lock carrier.

Removing:
– Removing headlight insert ⇒ page 189
– Unscrew height adjusting screw.
– Unscrew control motor positioning axle -arrow-.

– Release control motor from carrier frame by turning to left with

left headlight and clockwise to the right with right headlight
-arrow- and forcefully pull out of catch.
Installing:
– Press control motor into catch until fully engaged, counter‐
holding reflector through opening for twin filament bulb.
– Lock control motor by turning back to initial position.
– Screw positioning axle into control motor.
– Install headlight insert ⇒ page 189
– Attach connector.
– Check headlight settings and adjust if necessary
⇒ page 191

190 Rep. Gr.94 - Lights, bulbs, switches - exterior

 agen TransporterA1991 oes ➤ , Transporter 1996 ➤
AG. Volkswagen G d
ksw not
by Vol
Electrical system
gu - Edition 10.2004
ara
d
rise nte
o eo
1.5 Adjusting headlights
th
au ra
ss c

ce
e
nl

pt
du

an
itte
Note

y li
erm

ab
ility
ot p
Use a headlight adjusting unit when adjusting headlights. The

wit
, is n
specifications are located in the Maintenance Manual. ⇒ Mainte‐

h re
nance ; Booklet 33
hole

spec
es, in part or in w

t to the co
– Headlight range control adjuster -E102- in basic position
– Adjust right headlight with cross-head screwdriver at adjusting
screws -arrows-.

rrectness of i
Upper adjusting screw - side adjustment lower adjusting screw -
l purpos

height adjustment

nform
ercia

Note
m

at
om

ion
c

in t
Both adjustment screws on left-hand headlight are a mirror image.
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Headlights (short front end) ▸ 12.95 191

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

2 Headlights (long front end) 01.96 ▸

2.1 Assembly overview - headlights

Caution

To disconnect and connect the battery, the procedure descri‐

bed in the workshop manual should be strictly adhered to
⇒ page 29 .

Note

After any measures which could affect the headlight setting, the
headlights must be checked and if necessary adjusted
⇒ page 195 . Volkswa AG. gen AG
agen does
olksw not
yV gu
db ara
1 - Headlight unit rise nte
tho eo
au ra
❑ Removing and installing ss c
⇒ page 193 .

ce
e
nl

pt
du

an
❑ Adjusting headlights
itte

y li
⇒ page 195 .
erm

ab
ility
ot p

2 - Left side light bulb -M1- and

wit
, is n

right -M3-

h re
hole

❑ Bulb 12 V, 4 W

spec
es, in part or in w

❑ Removing and installing

t to the co
⇒ page 193 .
3 - Left headlight twin filament

rrectness of i
bulb/left headlight sealed
beam unit -L1- and right -L2-
l purpos

❑ Halogen bulb H4 12 V,
60 W/55 W
nf
ercia

❑ Removing and installing

rm

⇒ page 193 .
m

atio
om

n in
c

4 - Sealing cap
or

thi
te

sd
a

5 - Left headlight range control

iv

o
r
rp

motor -V48- and right -V49-

cu
o

m
f

en
ng

❑ Only vehicles with head‐

t.
yi Co
op
light range control C py
t. rig
gh ht
❑ Removing and installing yri
p by
o Vo
⇒ page 194 .
by c lksw
cted agen
Prote AG.
6 - Front left turn signal bulb -
M5- or front right -M7-
❑ Bulb 12 V, 21 W
❑ Removing and installing
turn signal bulb
⇒ page 200 .
7 - Front turn signal lamp
❑ Removing ⇒ page 200 .

192 Rep. Gr.94 - Lights, bulbs, switches - exterior

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

2.2 Renewing headlight bulbs

2.2.1 Removing and installing left headlight

twin filament bulb/left headlight sealed
beam unit -L1- or
olks
wright
agen -L2-
AG. Volkswagen AG d
oes
no
yV t gu
Removing: db ara
rise nte
tho eo
– Remove sealing cap
ss
on back of headlight unit. au ra
c

ce
le

– Pull connector off twin-filament bulb.

un

pt
an
d
itte

y li
– Release spring clamp -1- and swing downwards.
erm

ab
ility
ot p

– Pull bulb out of reflector.

wit
is n

h re
Installing:
ole,

spec
urposes, in part or in wh

t to the co
Note

Do not touch bulb glass when fitting bulbs. Fingers leave traces

rrectne
of grease on the bulb glass, which evaporate when the bulb is
switched on and cause the glass to cloud over.

ss o
cial p

f
– Insert new bulb so that the lugs on the disc plate align with the

inform
recesses in the reflector.
mer

atio
m

– Check functioning of headlight after installing a new bulb.

o

n
c

i
or

n
– Check headlight settings and adjust if necessary
thi
te

⇒ page 195 sd
iva

o
pr

cum
r
fo

en
ng

2.2.2 Removing and installing left side light

t.
yi Co
op py
bulb -M1- or right side light bulb -M3-
. C rig
ht ht
rig by
copy Vo
lksw
Removing:
by
cted agen
Prote AG.

– Remove sealing cap on back of headlight unit.

– Pull out bulb with holder on connector from reflector.
Installing:
– After changing bulb, push bulb with holder into reflector to
stop.
– Check functioning of headlight after installing a new bulb.
– Check headlight settings and adjust if necessary
⇒ page 195

2.3 Removing and installing headlight insert

Note

Headlight must be adjusted after any measures which could affect

the headlight setting

Removing:
– On vehicles with headlight washer system remove washer jet
brackets ⇒ page 182 .
– Remove end panel under headlight ⇒ General body repairs,
exterior; Rep. Gr. 66 ; Trim.

2. Headlights (long front end) 01.96 ▸ 193

 Transporter 1991 ➤ , Transporter agen1996 ➤
AG. Volkswagen AG d
oes
ksw not
Electrical system - Edition
by V 10.2004
o l
gu
a
ed ran
oris tee
– On vehicles with headlight
au
th
washer system remove washer jet or
ac
pop-up cylinder ⇒ page
ss 183

ce
le
un

pt
– Unscrew securing bolts -arrows- and pull out headlight unit

an
d
forwards. itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

– Unclip line connections on back of headlight, -arrows-.

m

– Disconnect headlight multi-pin connectors.

a
com

tion in
Installing:
r
te o

thi
s
iva

Installation is carried out in the reverse sequence of removal.

do
r
rp

cum
fo

– Check headlight settings and adjust if necessary

en
ng

t.
yi
⇒ page 195
Co
Cop py
t. rig
gh
– On vehicles with headlight washer system remove special tool
ht
pyri by
Vo
3093 again.
co lksw
by
cted agen
Prote AG.

2.4 Removing and installing left headlight

range control motor -V48- and right
headlight range control motor -V49-

Note

♦ The control motor can only be removed and installed when the
headlight housing has been removed.
♦ If control motors are removed and installed or renewed, al‐
ways carry out the headlight basic setting with a beam setting
appliance (inclination: see sticker or embossing on left hand
lock carrier.

Removing:
– Release left-hand headlight control motor by turning to right
and right-hand control motor by turning to left.
– Pull positioning shaft ball head out of location in reflector.
Installing:
– Press control motor into ball end mounting at reflector while
counterholding reflector through opening for twin-filament bulb
and locking positioning axle with reflector.
– Lock control motor in position by turning.
– Check headlight settings and adjust if necessary
⇒ page 195

194 Rep. Gr.94 - Lights, bulbs, switches - exterior

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

2.5 Adjusting headlights

Note

Use a headlight adjusting unit when adjusting headlights. The

specifications are located in the Maintenance Manual. ⇒ Mainte‐
nance ; Booklet 33

– Adjuster for headlight range control -E102- in basic position

– Adjust left headlight with a large cross-head screwdriver at
adjusting screws -arrows-.
Left adjusting screw - side adjustment right adjusting screw -
height adjustment swa
gen AG
. Volkswagen AG
does
k not
Vol gu
d by ara
e nte
ris
Note utho eo
ra
a c
ss

ce
le

Both adjustment screws on right-hand headlight are a mirror im‐

un

pt
age.

an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Headlights (long front end) 01.96 ▸ 195

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

3 Front fog lights (short front end) ▸

12.95

3.1 Removing and installing front fog lights

n AG. Volkswagen AG do
– Remove protective cap from housing. lkswage es n
o ot g
byV ua
d ran
– Disconnect connector. o
ir se tee
th or
u
– Unscrew cross-head bolts -arrows- and remove
ss fog light to‐
a ac
wards wheel housing.

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

3.2 Renewing front fog light bulb

nform
mercia

Note

at
om

ion
c

in t
or

Do not touch bulb glass when fitting bulbs. Fingers leave traces

his
ate

of grease on the bulb glass, which evaporate when the bulb is

do
riv

switched on and cause the glass to cloud over.

p

cum
for

en
ng

t.
yi Co
op
– Pull sealing cap -1- off housing. C py
t. rig
gh ht
yri
– Disconnect earth connector -2- and connector -3-.
p by
co Vo
by lksw
cted agen
– Release spring clip -4- and swing out.
Prote AG.

– Pull bulb with holder out of housing.

– Insert new bulb so that the recess in the bulb holder aligns with
guide lug of housing -5-.

3.3 Adjusting fog lights

– To adjust light range, turn adjusting screw -arrow.

196 Rep. Gr.94 - Lights, bulbs, switches - exterior

 Transporter 1991 ➤ , Transporter 1996 ➤
AG. Volkswagen AG d Electrical
system - Edition 10.2004
agen oes
olksw not
yV gu
db ara
rise nte
Note ut
ho eo
ra
s a c
s
♦ Adjusting wheel for height adjustment -arrow-

ce
e
nl

pt
du

an
itte
♦ There is no provision for lateral adjustment.

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
– To adjust the light range, turn adjusting wheel (with long
screwdriver through opening in bumper -arrow- ).
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3. Front fog lights (short front end) ▸ 12.95 197

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

4 Fog lights (long front end) 01.96 ▸

4.1 Removing and installing fog lights

– Pull off connector from protective cap.
– Unscrew Torx screws -arrows- and remove fog light towards
wheel housing.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
4.2 Renewing fog light bulb
hole

spec
es, in part or in w

– Pull off connector from protective cap.

t to the co
– Unscrew protective cap -1- from housing.

rrectness of i
– Disconnect earth connector -2- in light and disconnect con‐
nector -3- in protective cap housing.
l purpos

– Release spring clip -4- and swing out.

nform
ercia

– Pull bulb with holder out of housing.

m

at
om

ion
c

Note
in t
or

his
ate

do
riv

Do not touch bulb glass when fitting bulbs. Fingers leave traces
p

cum
or

of grease on the bulb glass, which evaporate when the bulb is

f

en
ng

switched on and cause the glass to cloud over.

t.
yi Co
Cop py
t. rig
gh ht
yri
– Insert new bulb so that the recess in the bulb holder aligns with p by
o Vo
by c lksw
guide lug of housing -5-. Prote
cted AG.
agen

4.3 Adjusting fog lights

– To adjust light range, turn adjusting screw -arrow.

Note

♦ Adjusting wheel for height adjustment -arrow-

♦ There is no provision for lateral adjustment.

198 Rep. Gr.94 - Lights, bulbs, switches - exterior

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

5 Front turn signal lamps (short front

end) ▸ 12.95

5.1 Removing and installing front turn sig‐

nals
– Press locking tab to the side and pull off turn signal housing
from headlight housing in direction of arrow.

5.2 Renewing front left turn signal bulb -M5-

and front right turn signal bulb -M7-
– Turn coupling inwards in direction of arrow and pull out of
housing.
olkswagen AG
en AG. V
– Remove bulb from bulb holder.olkswag does
not
yV gu
db ara
rise nte
tho eo
Note au ra
c
ss
ce
e
nl

Do not touch bulb glass when fitting bulbs. Fingers leave traces
pt
du

an

of grease on the bulb glass, which evaporate when the bulb is

itte

y li
erm

switched on and cause the glass to cloud over.

ab
ility
ot p

wit
, is n

– When installing, turn coupling until it engages (opposite direc‐

h re
hole

tion of arrow).
spec
es, in part or in w

– After installing a new bulb check function of turn signals.

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

5. Front turn signal lamps (short front end) ▸ 12.95 199

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

6 Front turn signal lamps (long front

end) 01.96 ▸
n AG. Volkswagen AG do
wage es n
6.1 Removing and installing front turn sig‐ olks ot g
byV ua
d ran
nals utho
ir se tee
or
s a ac
– Unhook spring -arrow- on inside of turn signal.
s

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Pull turn signal forwards in direction of -arrow- from headlight

housing.

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

6.2 Renewing front left turn signal bulb -M5-

and front right turn signal bulb -M7-
– Turn coupling at left turn signal inwards in direction of arrow
and pull out of housing. Loosen coupling at right turn signal by
turning coupling outwards.
– Remove bulb from bulb holder.

Note

Do not touch bulb glass when fitting bulbs. Fingers leave traces
of grease on the bulb glass, which evaporate when the bulb is
switched on and cause the glass to cloud over.

– When installing, turn coupling until it engages.

200 Rep. Gr.94 - Lights, bulbs, switches - exterior

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

7 Tail light

7.1 Removing and installing van tail light

Brake light, tail light and turn signal in left side panel:
AG. Volkswagen AG d
agen oes
1 - Lens olksw not
V gu
d by ara
❑ Removing orise nte
eo
⇒ Item 1 (page 201) . aut
h
ra
ss c
2 - Seal

ce
e
nl

pt
du

an
3 - Left side reversing light bulb
itte

y li
erm

-M16- and right -M17-

ab
ility
ot p

❑ 12 V, 21 W

wit
, is n

h re
4 - Rear left turn signal bulb -
hole

spec
M6- and right -M8-
es, in part or in w

❑ 12 V, 21 W

t to the co
5 - Left brake and tail light bulb
-M21- and right -M22-

rrectness of i
❑ 12 V, 21 W / 5 W
l purpos

6 - Bulb holder
7 - M5 hexagon nut with wash‐

nform
ercia

er
m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Remove housing:
– Pull connector from bulb holder.
– Unscrew hexagon nuts -arrows-.
– Release retaining tabs -1- and unscrew housing.

7. Tail light 201

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

7.2 Removing and installing drop-side tail light

1 - Bulb holder
2 - Rear fog light bulb -L20-
❑ only on driver side
❑ 12 V, 21 W
- Left side reversing light bulb -
M16- and right -M17-
❑ 12 V, 21 W
3 - Left side tail light bulb -M4-
and right -M2- n AG. Volkswagen AG do
wage
❑ 12 V, 10 W olks es n
ot g
byV ua
d ran
4 - Lens ir se tee
tho
u or
a ac
5 - Lens securing bolt ss

ce
le
un

6 - Left side brake light bulb -

pt
an
d
itte

M9- and right -M10-

y li
rm

ab
❑ 12 V, 21 W
pe

ility
ot

wit
, is n

- Rear left turn signal bulb -M6-

h re
and right -M8-
hole

spec
❑ 12 V, 21 W
es, in part or in w

t to the co
7 - Securing nut M6
8 - Washer

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

202 Rep. Gr.94 - Lights, bulbs, switches - exterior

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

8 Additional brake light

AG. Volkswagen AG d
The additional brake light is mounted at the rear
lksw window on ve‐
agen oes
not
hicles with rear lid. db
yV
o gu
a ran
ise tee
or
8.1 Removing and installing
s au
th additional or
ac
brake light bulb holder (rear lid)
s

ce
le
un

pt
an
d
– Pull off connector, press back retaining spring -arrows- and
itte

y li
take out bulb holder.
erm

ab
ility
ot p

Installation is carried out in the reverse sequence.

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
Exchange bulbs:
mer

atio
om

n
c

i
or

n
Note

thi
te

sd
iva

o
pr

c
Do not touch bulb glass when fitting bulbs. Fingers leave traces

um
r
fo

of grease on the bulb glass, which evaporate when the bulb is

en
ng

t.
yi
switched on and cause the glass to cloud over.
Co
Cop py
t. rig
gh ht
pyri by
– The bulbs (12 V, 5 W) -2- are plugged in. They can be pulled
o Vo
by c lksw
cted
out of and pushed into the bulb holder -1-.
agen
Prote AG.

8.2 Removing and installing additional

brake light housing (rear lid)
– Press back retaining springs -arrows- and take housing with
lens off rear window.
Installation is carried out in the reverse sequence.

8. Additional brake light 203

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

9 Number plate lights

9.1 Removing number plate lights n AG. Volkswagen AG do

lkswage es n
o ot g
– Unscrew cross-head bolts -arrows- of the particular
ed
by V number ua
ran
plate light and remove number plate light (12hor V, 5 W).
is tee
ut or
a ac
ss

ce
le
Note
un

pt
an
d
itte

y li
erm

♦ The light upper part is locked with the bulb socket. To change

ab
ility
bulb, bend back locking hooks and remove light upper part.
ot p

wit
is n

♦ After installing a new bulb check functioning of number plate

h re
ole,

light.

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

204 Rep. Gr.94 - Lights, bulbs, switches - exterior

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

10 Rear fog light

10.1 Removing rear fog light

– Press locking tab to left with screwdriver and remove rear fog
light forwards (12 V, 21 W).

Note

After installing a new bulb check functioning of rear fog light.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri by

205
cop Vo
by lksw
Prote
cted AG.
agen 10. Rear fog light
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

11 Steering column switch and ignition/

starter switch ▸08.98

11.1 Assembly overview - steering column

Caution

To disconnect and connect the battery, the procedure descri‐

bed in the workshop manual should be strictly adhered to
⇒ page 29 . swa
gen AG
. Volkswagen AG
does
olk not
yV gu
edb ara
ris nte
tho eo
au ra
c
ss
Note

ce
e
nl

pt
du

an
itte

♦ Further information on assembling the steering column ⇒

y li
erm

ab
Running gear, axles, steering as of January 1996; Rep. Gr.

ility
ot p

48 ; Assembly overview: steering column, outer sleeve and

wit
steering wheel > 08.98
, is n

h re
hole

♦ Instructions for working on vehicles fitted with an airbag ⇒

spec
General body repairs, interior; Rep. Gr. 69 ; Airbag .
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

206 Rep. Gr.94 - Lights, bulbs, switches - exterior

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1 - Cover cap for horn plate

❑ Removing cover cap
⇒ page 208
2 - Contact plate for horn plate
❑ Removing contact plate
⇒ page 208
3 - Hexagon nut
❑ 70 Nm
4 - Steering wheel
❑ Contact ring for horn
plate ⇒ page 208
5 - Securing bolts for steering
column switch
6 - Switch for turn signals, AG. Volkswagen AG d
cruise control system, main agen oes
olksw not
and dipped beam, headlight d by
V gu
ara
flasher and hazard warning orise nte
eo
light switch aut
h
ra
ss c
❑ Removing ⇒ page 208 .

ce
e
nl

pt
du

an
7 - Windscreen wiper switch,
itte

y li
wiper-washer operation and
erm

ab
multi-function indicator switch

ility
ot p

wit
❑ Removing ⇒ page 208 .
, is n

h re
hole

8 - Trim - upper part

spec
es, in part or in w

9 - Trim - lower part

t to the co
10 - Outer sleeve

rrectness of i
11 - Steering column
l purpos

12 - Support ring
13 - Securing bolt for steering

nform
ercia

lock housing
m

❑ 10 Nm

at
om

ion
c

14 - Steering lock housing

in t
or

his
e

❑ Removing and installing ⇒ page 210 .

at

do
priv

cum
15 - Ignition/starter switch -D-
for

en
ng

t.
yi
❑ Remove steering lock housing, then unscrew securing bolt
Co
Cop py
t. rig
16 - Lock cylinder
gh ht
pyri by
Vo
o
by c
❑ Removing and installing ⇒ page 212 .
lksw
cted agen
Prote AG.
17 - Spring
18 - Clamping washer

11. Steering column switch and ignition/starter switch ▸08.98 207

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

Remove cover cap:

– Lift upper cover cap and pull off from steering wheel in direc‐
tion of arrow.

Note

Under the cover cap are three springs that keep the cover cap
and contact plate underneath apart ⇒ page 208 AG. Volkswagen A
agen G do
es n
ksw
y Vol ot g
ua
b
ed ran
oris tee
th or
au ac
ss
Remove contact plate for horn plate:

ce
e
nl

pt
du

an
– Remove springs -1- from contact plate.
itte

y li
erm

ab
– Press contact plate in direction of arrow and pull off upwards

ility
ot p

from steering wheel.

wit
, is n

h re
– Disconnect connecting lines.
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Contact ring for horn plate

nf
ercia

o
The positive voltage is fed to the horn plate button via a spring

rm
m

contact on the turn signal switch and a slip ring -arrow- under the

atio
m

steering wheel.
o

n in
or c

thi
e

Coat with grease G 000400.

t

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

11.2 Removing and installing steering col‐

umn switch
– Remove steering wheel.
– Remove trim lower part.
– Remove securing bolts -arrows-.
– Disconnect connectors for turn signal and windscreen wiper
switch.
– Pull off turn signal and windscreen wiper switch with trim upper
part from steering column.

208 Rep. Gr.94 - Lights, bulbs, switches - exterior

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

11.3 Pin assignment on steering column

switch and ignition/starter switch
11.3.1 A - Ignition/starter switch
1 - Ignition/starter switch - terminal 15
2 - Ignition/starter switch - terminal X
3 - Ignition/starter switch - terminal 50
4 - Ignition/starter switch - terminal 30
5 - Ignition/starter switch - terminal SU AG. Volkswagen AG d
agen oes
lksw not
6 - Ignition/starter switch - terminaldP by
Vo gu
ara
ise nte
or eo
h
aut ra
ss c

ce
le

11.3.2 B - Connector, 5 pin

un

pt
an
d
itte

y li
1 - Windscreen wiper switch - terminal 53b
erm

ab
ility
ot p

2 - Windscreen wiper switch - terminal 53a

wit
is n

h re
ole,

3 - Windscreen wiper switch - terminal 53

spec
urposes, in part or in wh

4 - Windscreen wiper switch - terminal 53e

t to the co
5 - Windscreen wiper switch - terminal J

rrectness o
cial p

f
11.3.3 C - Connector, 5 pin

inform
mer

1 - Hazard warning light switch - terminal 49

atio
om

n
c

2 - Switch for dipped beam/headlight flasher - terminal 56b

i
or

n thi
te

sd
a

3 - Switch for dipped beam and headlight flasher - terminal 56

iv

o
pr

cum
r
fo

4 - Switch for dipped beam/headlight flasher - terminal 56a

en
ng

t.
yi Co
op
5 - Switch for dipped beam and headlight flasher - terminal 30 C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

11.3.4 D - Connector, 4 pin

1 - Windscreen wiper switch - terminal L
2 - Windscreen wiper switch - terminal T
3 - Windscreen wiper switch - terminal 31
4 - Hazard warning light switch - terminal 15

11. Steering column switch and ignition/starter switch ▸08.98 209

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

11.3.5 E - Connector, 7 pin

1 - Horn plate - terminal 71
2 - Hazard warning light switch - terminal 49a
3 - Turn signal switch - terminal L
4 - Parking light switch - terminal PL
5 - Parking light switch - terminal P
6 - Parking light switch - terminal PR
7 - Turn signal switch - terminal R agen
AG. Volkswagen AG d
oes
olksw not
y V gu
d b ara
11.4 Pin assignment at connector for multi- thorise nte
eo
function indicator (MFI) and cruise con‐ au ra
ss c

ce
trol system (CCS) (at steering lock
e
nl

pt
du

an
housing)
itte

y li
erm

ab
ility
ot p

11.4.1 A - Connector, 4 pin, switch for MFI

wit
, is n

h re
1 - Terminal 31
hole

spec
es, in part or in w

2 - Functioning (mode)

t to the co
3 - Memory switchover (Memory)
4 - Delete (Reset)

rrectness of i
l purpos

nform
mercia

at
om

io
11.4.2 B - Connector, 4 pin, switch for CCS

n
c

in t
or

his
ate

1 - On

do
priv

cum
or

2 - Mounting
f

en
ng

t.
yi Co
op
3 - Store (FIX) C py
t. rig
gh ht
yri by
4 - Terminal 15 cop Vo
by lksw
cted agen
Prote AG.

11.5 Removing and installing steering lock

housing
Special tools and workshop equipment required

210 Rep. Gr.94 - Lights, bulbs, switches - exterior

 n AG. Volkswagen AGTransporter 1991 ➤ , Transporter 1996 ➤
lkswage does
not Electrical system - Edition 10.2004
Vo gu
by ara
ed nte
ris
♦ Tube -VW 420- utho eo
ra
a c
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

♦ Vernier caliper
♦ Hammer

nform
ercia

Removing:
m

at
om

io
– Remove steering column switches ⇒ page 208 .

n
c

in t
or

his
e

– Drill out securing bolts for steering lock housing.

at

do
priv

c
– Pull off clamping washer and spring from steering column.

um
for

en
ng

t.
yi Co
Cop py
.
Note
t rig
gh ht
pyri by
Vo
co lksw
by
cted
The steering column is pulled away downwards after the clamping
agen
Prote AG.
washer is pulled off.

– Pull off steering lock housing from outer sleeve and steering
column.
Installing:

Note

The steering lock housing can be installed only with the steering
column removed ⇒ Running gear, axles, steering as of January
1996; Rep. Gr. 48 ; Removing and installing outer sleeve with
steering column .

– Place outer sleeve of removed steering column in vice; sup‐

port universal joint -a- on the vice.
– Screw vice together.
– Place steering lock housing on outer sleeve.

11. Steering column switch and ignition/starter switch ▸08.98 211

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Push steering lock housing onto outer sleeve until dimension

-a- is attained.
a - = 95 mm
– Tighten shear bolt for steering lock housing until bolt head
breaks off.
– Slide spring and clamping washer onto steering column.

– Drive clamping washer with pipe -VW 420- onto steering col‐
umn until installation position is attained.

AG. Volkswagen AG d
agen oes
Installation position of clamping washer olksw not
byV gu
ara
d
a - = 65 mm orise nte
eo
h
ut ra
b - = clamping washer ss a c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

11.6 Removing and installing lock cylinder

rrectness of i

Removing:
l purpos

– Remove steering lock housing ⇒ page 210 .

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

212 Rep. Gr.94 - Lights, bulbs, switches - exterior

 Transporter e1991 . V➤
olk,sw
Transporter
agen AG 1996 ➤
g n AG does
ol swa
kElectrical system - Edition 10.2004
not
V y gua
db ran
rise tee
– Mark steering lock housing for drilling tho or
s au ac
a - = 12 mm s

ce
e
nl

pt
du
b - = 10 mm

an
itte

y li
erm

ab
– Drill steering lock housing (approx. 3 mm) until the lock cylin‐

ility
ot p
der detent spring can be felt (hole depth approx. 3 mm).

wit
, is n

h re
– Using opposite end of drill compress lock spring and pull out

hole

spec
lock cylinder.

es, in part or in w

t to the co
Installing:

WARNING

rrectness of i
l purpos
Steering lock housing which has been drilled must not be in‐
stalled again.

nf
ercia

orm
m

– Push lock cylinder into steering lock housing.

atio
om

n in
c

– By slightly turning key in lock cylinder it can be pushed in onto

or

thi
e

stop.
t

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

11. Steering column switch and ignition/starter switch ▸08.98 213

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

12 Steering column switch and ignition/

starter switch 08.98 ▸

12.1 Assembly overview - steering column

Caution

To disconnect and connect the battery, the procedure descri‐

bed in the workshop manual should be strictly adhered to
n AG. Volkswagen AG do
⇒ page 29 . olkswage es n
o
yV t gu
db ara
ir se nte
ho eo
aut ra
ss c
Note

ce
le
un

pt
an
d
itte

y li
♦ Further information on assembling the steering column ⇒
rm

ab
Running gear, axles, steering as of January 1996; Rep. Gr.
pe

ility
48 ; Assembly overview: steering column, outer sleeve and
ot

wit
, is n

steering wheel > 08.98 .

h re
hole

spec
♦ Instructions for working on vehicles fitted with an airbag ⇒
es, in part or in w

General body repairs, interior; Rep. Gr. 69 ; Airbag

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

214 Rep. Gr.94 - Lights, bulbs, switches - exterior

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1 - Cover cap for horn plate

2 - Hexagon nut
❑ 67 Nm
3 - Steering wheel
4 - Spacer bush
AG. Volkswagen AG d
5 - Securing bolts for lsteering
ksw
agen oes
not
column switch d by Vo gu
ara
e nte
ris
6 - Switch for tho turn signals, eo
au system, main
cruise control
s
ra
c
s
and dipped beam and head‐

ce
le
un

pt
light flasher

an
d
itte

y li
❑ Removing ⇒ page 215 .
erm

ab
ility
ot p

7 - Switch for windscreen and

wit
is n

rear window wipers, wiper-

h re
ole,

washer operation and switch

spec
for multi-function indicator
urposes, in part or in wh

t to the co
❑ Removing ⇒ page 215 .
8 - Trim - upper part

rrectne
9 - Trim - lower part
10 - Outer sleeve

ss o
cial p

f
11 - Steering column
inform
mer

12 - Support ring
atio
m

13 - Securing bolt for steering

o

n
c

i
or

lock housing
thi
te

sd
a

❑ 10 Nm
iv

o
pr

cum
r
fo

14 - Steering lock housing

en
ng

t.
yi Co
❑ Removing and installing Cop py
t. rig
⇒ page 216 . opyri
gh by
Vo
ht
by c lksw
15 - Ignition/starter switch -D- Prote
cted AG.
agen

❑ Remove steering lock

housing, then unscrew
securing bolt
16 - Lock cylinder
❑ Removing and installing ⇒ page 217 .
17 - Spring
18 - Clamping washer

12.2 Removing and installing steering col‐

umn switch
Removing:
– Remove steering wheel.

Note

Vehicles with driver side airbag ⇒ General body repairs, interior;

Rep. Gr. 69 ; Airbag .

– Remove trim under steering column switch.

12. Steering column switch and ignition/starter switch 08.98 ▸ 215

 AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Transporter 1991 ➤ , Transporter
thor 1996 ➤ eo
u ra
Electrical system - Edition
ss a 10.2004 c

ce
e
nl

pt
du

an
itte

y li
Note

erm

ab
ility
ot p

wit
The self-diagnosis connecting bush is engaged in the lower trim.
, is n

h re
Removal of the connecting bush is necessary only if the footwell
hole

spec
trim disturbs further work.
es, in part or in w

t to the co
– Remove trim above steering column switch.
– Pull connector -1- off the steering column in direction of arrow.

rrectness of i
– Disconnect connectors for turn signal and windscreen wiper
l purpos

switch.

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ercia

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om

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thi
te

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– Remove securing bolts -arrows-.

– Pull off turn signal and windscreen wiper switch from steering
column.
Installing:
– Install in reverse order of removal.

12.3 Removing and installing steering lock

housing
Removing:
– Remove steering column switch ⇒ page 215
– Pull connector off steering lock housing.
– Drill out securing bolt for steering lock housing.
– Screw hexagon nut for securing steering wheel onto steering
column.
– Remove clamping washer.
– Pull off steering housing from outer sleeve and steering col‐
umn tube.
Installing:
– Attach steering lock housing and loosely screw together with
a new shear bolt.

216 Rep. Gr.94 - Lights, bulbs, switches - exterior

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Pull on clamping washer ⇒ Running gear, axles, steering as

of January 1996; Rep. Gr. 48 ; Assembly overview: steering
column, outer sleeve and steering wheel > 08.98 .
Remainder of installation procedure is carried out in reverse order
n AG. Volkswagen AG do
of removal. olks
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12.4 Removing
tho
ris
e
and installing lock cylinder
an
tee
or
au ac
Removing:
ss

ce
le
un

pt
– Remove steering lock housing ⇒ page 216

an
d
itte

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– Mark steering lock housing for drilling
rm

ab
pe

ility
ot

a - = 12 mm

wit
, is n

h re
b - = 10 mm
hole

spec
es, in part or in w

– Drill steering lock housing (approx. 3 mm) until the lock cylin‐

t to the co
der detent spring can be felt (hole depth approx. 3 mm).
– Using opposite end of drill compress lock spring and pull out

rrectness of i
lock cylinder.
l purpos

Installing:

nform
ercia

WARNING
m

a
com

Steering lock housing which has been drilled must not be in‐
stalled again. tion in
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te o

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s
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– Push lock cylinder into steering lock housing.

fo

en
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– By slightly turning key in lock cylinder it can be pushed in onto
t. Cop py
stop.
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12.5 Pin assignment on steering column
Prote AG.

switch and ignition/starter switch

12.5.1 A - Ignition/starter switch
1 - Ignition/starter switch - terminal 15
2 - Ignition/starter switch - terminal X
3 - Ignition/starter switch - terminal 50
4 - Ignition/starter switch - terminal 30
5 - Ignition/starter switch - terminal SU
6 - Ignition/starter switch - terminal P

12.5.2 B - Connector, 5 pin

1 - Windscreen wiper switch - terminal 53b
2 - Windscreen wiper switch - terminal 53a
3 - Windscreen wiper switch - terminal 53
4 - Windscreen wiper switch - terminal 53e
5 - Windscreen wiper switch - terminal J

12. Steering column switch and ignition/starter switch 08.98 ▸ 217

 Transporter 1991 ➤ w, aTransporter
gen AG
. Volksw1996 ➤doe
agen AG
ks s no
Electrical system
by V - Edition 10.2004
o l t gu
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ed ran
oris tee
12.5.3 C - Connector, 5 pin
th or
au ac
ss

ce
le
1 - Not assigned
un

pt
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2 - Switch for dipped beam/headlight flasher - terminal 56b
rm

ab
pe

ility
3 - Switch for dipped beam and headlight flasher - terminal 56
ot

wit
, is n

h re
4 - Switch for dipped beam/headlight flasher - terminal 56a
hole

spec
5 - Switch for dipped beam and headlight flasher - terminal 30
es, in part or in w

t to the co
rrectness of i
l purpos

12.5.4 D - Connector, 4 pin

1 - Windscreen wiper switch - terminal L

nform
ercia

2 - Windscreen wiper switch - terminal T

m

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tio
3 - Windscreen wiper switch - terminal 31

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4 - Hazard warning light switch - terminal 15

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12.5.5 E - Connector, 7 pin
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1 - Horn plate - terminal 71
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2 - Turn signal switch - terminal 49a cop Vo
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3 - Turn signal switch - terminal L
AG.

4 - Parking light switch - terminal PL

5 - Parking light switch - terminal P
6 - Parking light switch - terminal PR
7 - Turn signal switch - terminal R

12.6 Pin assignment at connector for multi-

function indicator (MFI) / rear window
wiper and cruise control system (CCS)
(at steering lock housing)
12.6.1 A - Connector, 5 pin, switch for MFI and
rear window wiper
1 - Terminal 31
2 - Functioning (mode)
3 - Memory switchover (Memory)
4 - Delete (Reset)
5 - Rear window wiper switch

12.6.2 B - Connector, 4 pin, switch for CCS

1 - On
2 - Mounting
3 - Store (FIX)
4 - Terminal 15

218 Rep. Gr.94 - Lights, bulbs, switches - exterior

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

96 – Lights, bulbs, switches - interior

1 Immobilizer

1.1 Assembly overview - immobilizer

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1 - Immobilizer control unit - wage does
J362- Volks not
gu
by ara
ed
❑ Location ⇒ page 219 . horis nte
eo
t
au ra
2 - Immobilizer reading coilss - c
D2- , fitted on steering lock

ce
e
nl

pt
du

housing

an
itte

y li
❑ Removing and installing
erm

ab
ility
⇒ page 219 .
ot p

wit
, is n

3 - Transponder (response-

h re
hole

reader memory) integrated in

spec
ignition key
es, in part or in w

t to the co
❑ ⇒ page 220
4 - Fuel cut-off valve control

rrectness of i
unit -J366- on diesel injection
pump
l purpos

❑ Removing and installing

⇒ page 221 .

nf
ercia

❑ retrofit ⇒ page 225

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1.2 Immobilizer control unit -J362-

The immobilizer control unit -J362- is located at the right bracket
of the dash panel insert.

1.3 Removing and installing immobilizer

reader coil -D2-
Removing:
– Remove lower and upper part of trim on steering column
switch.

1. Immobilizer 219
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Pull reading coil off steering lock housing.

– Pull connector off immobilizer control unit.
Installing:
Install in reverse order of removal.

1.4 Transponder
Renewal of the transponder (response reader memory) in the ig‐
nition key is not possible.
The complete ignition key must always be renewed if the trans‐
ponder is defective ⇒ Electrical system, self-diagnosis; Rep. Gr.
01 ; Guided functions for immobilizer; Adapting ignition keys.

1.5 Fuel shut-off valve control unit -J366-

1.5.1 Assembly overview - fuel shut-off valve control unit

AG. Volkswagen AG d
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aut ra
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erm

ab
ility
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wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
r
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

220 Rep. Gr.96 - Lights, bulbs, switches - interior

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

A - Fuel shut-off valve -N109-

1 - M5 hexagon nut
2 - Clamp
3 - Lower part of cover cap
4 - Upper part of cover cap
5 - Fuel shut-off valve control
unit -J366-
6 - Shear bolts
❑ Grease (blister packing)

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rm

ab
1.5.2 Removing and installing fuel shut-off
pe

ility
ot

wit
valve control unit -J366-
, is n

h re
hole

spec

Removing:
es, in part or in w

t to the co

– Unscrew hexagon bolt and washer assemblies and hexagon

nuts -arrows-, release locking lever, swing down noise insu‐
lation tray and unhook at brackets.
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
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fo

en
ng

t.
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Cop py
t. rig
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pyri by
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cted agen
Prote AG.

1. Immobilizer 221
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Unscrew left and right securing bolts -1-.

– Fold out radiator and lock carrier -arrow-.
– Remove injector lines as a complete set ⇒ Diesel direct fuel
injection and glow plug system; Rep. Gr. 23 .

Note

No fuel must spill on hoses or lines!

Note

♦ If the control unit must be removed because of a defective fuel

shut-off valve, when drilling out the shear bolts be sure not to
damage the control unit, as it can be reused after the fuel shut-
off valve is repaired.
♦ The shear bolts are individually available under the part num‐
ber 028 903 285.

– Disconnect 2-pin connector for the fuel shut-off valve control

unit. en AG. V
olkswagen AG
ag does
ksw not
y Vol gu
– Centre-punch shear bolt heads -arrows-. ed
b ara
nte
oris eo
h
– ut shear bolt heads
Drill approximately 4 mm intos athe with a drill ra
c
(3 mm diameter). s

ce
e
nl

pt
du

– Unscrew shear bolts using a left-handed screw drill.

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

– Pull fuel shut-off valve control unit -1- from fuel shut-off valve
-A-.
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

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for

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Cop py
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

222 Rep. Gr.96 - Lights, bulbs, switches - interior

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Detach cover cap upper part -2- from cover cap lower part
-1- and pull out of catch.

AG. Volkswagen AG d
agen oes
olksw not
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tho eo
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ce
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nl

pt
du

an
itte

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erm

ab
ility
ot p

– Unscrew hexagon nut -1- and remove cover cap lower part

wit
, is n

-4- and fuel shut-off valve control unit single line -2- from fuel

h re
hole

shut-off valve -3-.

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

– Remove clamp -2- behind fuel shut-off valve -1-.

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
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cted agen
Prote AG.

Installing:
– Grease semi-circular surface of clamp -2- with provided
grease.
– Insert clamp -2- behind fuel shut-off valve -1-.
– Also grease the clamping surfaces with provided grease on
fuel shut-off valve control unit.

Note

Screwed connection surfaces and threaded holes must be free of

grease!

1. Immobilizer 223
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Firmly screw cover cap lower part -4- and fuel shut-off valve
control unit single line -2- to fuel shut-off valve -3- with hexagon
nut -1-.
Torque setting: 1.5 Nm.
After screwing, the terminal must have the position shown in the
figure.

– Slide cover cap upper part -2- as shown over hexagon nut onto
cover cap lower part -1- and snap in.

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agen oes
o lksw not
byV gu
ara
ed
– Slide fuel cut-offhorivalve
s control unit -1- onto fuel cut-off valve
nte
eo
-A- until control
s aut unit lies against valve. ra
c
s
The single line -X- must not be pinched.
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne

– At first only hand-tighten securing bolts (shear bolts) -1- so that

the bolt heads do not break off.
ss o
cial p

f inform

Note
mer

atio
om

Once the bolt heads are sheared off the securing bolts cannot be
n
c

i
or

unscrewed again! The securing bolts must therefore be finally

thi
te

sd

tightened only after the immobilizer is functionally checked.

iva

o
pr

cum
r
fo

en
ng

– Re-install injector lines as a complete set ⇒ Diesel direct fuel

t.
yi Co
injection and glow plug system; Rep. Gr. 23 . Cop py
ht. rig
rig ht
– Connect 2-pin connector from fuel cut-off valve control unit to py by
co Vo
by lksw
open connector (see current flow diagram). Prote
cted AG.
agen

– Secure line.
– Install engine compartment cover (noise insulation):
– When installing tighten bolts and nuts.
Torque setting: 9 Nm.
– Fit radiator and lock carrier again.

224 Rep. Gr.96 - Lights, bulbs, switches - interior

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

1.5.3 Retrofitting fuel cut-off valve control unit

-J366-

Note

♦ When retrofitting the vehicle diagnosis, testing and information

system -VAS 5051 A- or vehicle diagnosis and service infor‐
mation system -VAS 5052- are required.
♦ Before starting retrofitting, check whether the fuel shut-off
valve -N109- wiring harness contains a 2-pin connector. It is
also possible to check if the immobilizer is fitted with vehicle
diagnosis, testing and information system -VAS 5051 A- or
vehicle diagnosis and service information system -VAS 5052-
via address word 25 “Immobilizer”.
♦ In vehicles without a 2-pin connector, retrofitting the control
unit for a fuel shut-off valve is not possible.

The retrofit set “control unit for fuel shut-off valve” is made up of:
♦ M5 hexagon nut ⇒ Item 1 (page 221)
♦ Clamp ⇒ Item 2 (page 221)
♦ Lower part of cover cap ⇒ Item 3 (page 221)
♦ Upper part of cover cap ⇒ Item 4 (page 221)
♦ Fuel shut-off valve control unit -J366- ⇒ Item 5 (page 221)
♦ Shear bolt and Grease (blister packing) ⇒ Item 6 (page 221)
Retrofitting fuel cut-off valve control unit -J366- :
– Unscrew hexagon bolt and washer assemblies and hexagon
nuts -arrows-, release locking lever, swing down noise insu‐
lation tray and unhook at brackets. n AG. Volkswagen A age G do
ksw es n
y Vol ot g
ua
b
ed ran
oris tee
th or
au ac
ss
ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

– Unscrew left and right securing bolts -1-.

h re
hole

spec

– Fold out radiator and lock carrier -arrow-.

es, in part or in w

t to the co

– Switch off ignition.

– Remove injector lines as a complete set ⇒ Diesel direct fuel
rrectness of i

injection and glow plug system; Rep. Gr. 23 .

l purpos

Note
nform
ercia

No fuel must spill on hoses or lines!

m

a
com

tion in

– Disconnect 2-pin connector for the fuel shut-off valve ⇒ Cur‐

r
te o

thi

rent flow diagrams, Electrical fault finding and Fitting locations.

s
iva

do
r
rp

– Disconnect and remove line at fuel shut-off valve.

um
fo

en
ng

t.
yi
The removed line is no longer needed.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Immobilizer 225
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Grease semi-circular surface of clamp -2- with provided

grease.
– Insert clamp -2- behind fuel shut-off valve -N109- -1-.
– Also grease the clamping surfaces with provided grease on
fuel shut-off valve control unit -J366- .
Screwed connection surfaces and threaded holes must be free of
grease!

– Using hexagon nut -1-, firmly screw cover cap lower part -4-
and single cable -2- of the fuel shut-off valve control unit -1- to
fuel shut-off valve -N109- -3-, 1.5 Nm +1 Nm.
After screwing, the terminal must have the position shown in the
figure. wage
n AG. Volkswagen AG do
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d by ara
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ris
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ra
a c
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

– Slide cover cap upper part -2- as shown over hexagon nut onto h re
cover cap lower part -1- and snap in.
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

– Slide fuel shut-off valve control unit -J366- -1- onto fuel shut-
thi
te

sd
a

off valve -N109- -A- until control unit lies against valve.
iv

o
r
rp

cu
o

The single line -X- must not be pinched.

f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

226 Rep. Gr.96 - Lights, bulbs, switches - interior

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– At first only hand-tighten securing bolts (shear bolts) -1- so that

the bolt heads do not break off.

Note

Once the bolt heads are sheared off the securing bolts cannot be
unscrewed again! The securing bolts must therefore be finally
tightened only after the immobilizer is functionally checked.

– Re-install injector lines as a complete set ⇒ Diesel direct fuel

injection and glow plug system; Rep. Gr. 23 .
– Connect 2-pin connector from fuel cut-off valve control unit to
open connector (see current flow diagram).
– Secure line as with previous line.
Adapting fuel shut-off valve control unit -J366- to immobilizer con‐
trol unit -J362- :

Note
olkswagen AG
en AG. V
♦ In the delivered condition the fuel
olksshut-off valve control units not
wag doe
always switches on the fueledshut-off
by
V
valve, even when not en‐ gu
ara
abled by the immobilizerhocontrol
ris unit. nte
eo
t
au ra
♦ The fuel shut-off valve
ss control unit -J366- must be adapted to c
the immobilizer control unit -J362- to ensure correct function‐

ce
le
un

pt
ing of the immobilizer.

an
d
itte

y li
erm

ab
ility
– Adapt fuel shut-off valve control unit -J366- to the immobilizer
ot p

control unit -J362- ⇒ Electrical system, self-diagnosis; Rep.

wit
is n

h re
Gr. 01 ; Guided functions for immobilizer; Adaption after
ole,

changing engine control unit . spec

urposes, in part or in wh

Carrying out functional check of immobilizer:

t to the co

– Start engine and let run at least 10 seconds.

rrectne

– Interrogate fault memory ⇒ Electrical system, self-diagnosis;

Rep. Gr. 01 ; Immobilizer self-diagnosis; Performing immo‐
bilizer self-diagnosis; Interrogating fault memory .
ss o
cial p

If a fault is detected:
inform
mer

– Remove fault using fault table ⇒ Electrical system, self-diag‐

atio
m

nosis; Rep. Gr. 01 ; Immobilizer self-diagnosis; Fault table .

o

n
c

i
or

– Delete fault memory ⇒ Electrical system, self-diagnosis; Rep.

thi
te

sd

Gr. 01 ; Immobilizer self-diagnosis; Performing immobilizer

iva

o
r

self-diagnosis; Deleting fault memory .

p

cum
r
fo

en
ng

t.
– Interrogate fault memory again ⇒ Electrical system, self-di‐ op
yi Co
agnosis; Rep. Gr. 01 ; Immobilizer self-diagnosis; Performing
C py
t. rig
gh
immobilizer self-diagnosis; Interrogating fault memory .
ht
pyri by
Vo
co lksw
by
If no fault is detected:
cted agen
Prote AG.

1. Immobilizer 227
 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Alternately tighten securing bolts (shear bolts) -1- until bolt

heads break off. This operation is easiest when performed
from the underside of the vehicle.
– Install engine compartment cover (noise insulation):
– When installing tighten bolts and nuts to 9 Nm.
. Volkswagen AG
wa gen AG does
– Fit radiator and lock carrierVagain.
olks not
gu
by ara
d
Enter retrofitting in serviceoris schedule with the following text:
e nte
eo
h
ut ra
“S085 (date/stamp)”s s a c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

228 Rep. Gr.96 - Lights, bulbs, switches - interior

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

2 Interior lights and switches

2.1 Removing and installing light switch

– On the left above the instrument illumination regulator insert a
slender object, such as a feeler gauge, max. 0.9 mm into the
joint between the light switch and the fresh air vent.
– Press catches to the right -arrow- and pull out light switch at
rotary knob.
– Pull off connector.

AG. Volkswagen AG d
agen oes
ksw
2.2 Removing and installing headlight range ol not
V gu
d by ara
e
control adjuster -E102- ris nte
ho eo
aut ra
s c
– Remove light switch. s

ce
e
nl

pt
du

– Press locating lugs on sides of headlight range control regu‐

an
itte

y li
lator inwards, so that the locating lugs disengage.
erm

ab
ility
ot p

– Pull headlight range control regulator to rear out of front plate

wit
, is n

of light switch.

h re
hole

spec
– Pull off connector.
es, in part or in w

t to the co
2.3 Removing and installing switches in
centre of dash panel ▸ 12.95

rrectness of i
Removing and installing
l purpos

♦ Hazard warning light switch

♦ Combination warning lamp

nf
ercia

orm
♦ Heated rear window switch
m

atio
om

n in
♦ Power window switch
or c

thi
te

♦ Heated seat adjuster

sd
iva

o
r
rp

cu

is the same for all switches and is described for only one switch.
o

m
f

en
ng

t.
yi Co
Removing switch: t. Cop py
rig
gh ht
yri
– Insert slender screwdriver or the like (e.g. feeler gauge) be‐ p by
o Vo
by c
tween switch housing and trim and cautiously detach switch.
lksw
cted agen
Prote AG.
– Pull switch out of dash panel.
– Pull off connector.
Install switch:
Install in reverse order of removal.

2. Interior lights and switches 229

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

2.4 Removing and installing switches in

centre of dash panel 01.96 ▸
Removing and installing
♦ Combination warning lamp (only vehicles with tachograph)
♦ Heated rear window switch
♦ Heated seat adjuster
♦ Switches for other optional equipment
is the same for all switches and is described for only one switch.
Removing switch: n AG. Volkswagen AG do
swage es n
– Pull ashtray out of mounting in dash panel. byV
olk ot g
ua
d ran
ir se
– Carefully detach switch trim catch starting at ashtray
th cutout
o tee
or
-arrows- and remove switch cover. ss
au ac

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– Pull switch out of dash panel mounting -arrows-.
l purpos

– Release connectors and pull off.

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Install switch:

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– Reconnect connector.
om

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– Push switch into mounting and engage

or

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– Fit switch trim and engage.

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230 Rep. Gr.96 - Lights, bulbs, switches - interior

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

97 – Wiring
1 Relay plate

1.1 Removing and installing relay plate

WARNING
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Before working on the electrical systemyV
o disconnect the battery s not g
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earth strap. ris
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1.1.1 Removing and installing relay plate ▸

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Note

h re
ole,

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urposes, in part or in wh

The relay plate with fuse holder is located behind the dash panel

t to the co
on the left. Removal of dash panel trim ⇒ General body repairs,
interior; Rep. Gr. 70 ; Dash panel

rrectne
– Press securing clips -1- on left and right of relay plate in di‐
rection of arrow until locking pins -2- at the clips are pulled out

s
of the retaining arm recesses -4-.

s o
cial p

f i
– Swing securing clips -1- forwards and pull off from pins -3- at

nform
relay plate.
mer

atio
m

– Press left retaining arm -4- outwards until pin -5- is pulled out
o

n
c

of arm and then detach relay plate.

i
or

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sd
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During installation pin -5- and locking pins -2- must engage in
iv

o
pr

retaining arm recesses.

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01.96 ▸

Note

The relay plate with fuse holder is located behind a cover for the
relay plate on the driver side.

– Turn locking knob -arrow- anti-clockwise. Then open relay

plate cover and unhook dash panel trim.
– Detach multi-fuse adapter -3- from catches at lower right and
left and pull out of brackets towards passenger compartment.

Note

Removal of the reinforcement plate -1- is not always necessary

for removal of the relay plate -2-, but it does facilitate access.

1. Relay plate 231

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Remove reinforcement plate -1-.

– Release securing clips -1- from pins -2- on left and right of relay
. Volkswagen AG
plate and swing upwards. swa
gen AG does
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– Press left retaining arm outwards, until the locking sdevice
db
y
on ara
i e nte
the relay plate is pulled out of the hole of the retaining
thor arm. eo
a u ra
c
– Unhook relay plate from retaining arms -3-. ss

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When installing, ensure the relay plate locking device engages in

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itte

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the hole of the retaining arm. The securing clips are locked on the
erm

ab
pins.

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1.2 Removing and installing multi-pin con‐
nector on back of relay plate

rrectness of i
l purpos

Note

nform
ercia

Multi-pin connector pin assignment ⇒ Current flow diagrams,

Electrical fault finding and Fitting locations
m

at
om

ion
c

in t
r

Remove multi-pin connector:

o

his
ate

do
riv

– Pull locking slide -1- on back of relay plate out of housing to

p

cum
or

stop (approx. 5 mm) -arrow-.

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232 Rep. Gr.97 - Wiring

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

– Press fasteners on multi-pin connector -arrow- and pull multi-

pin connector out of relay plate.

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Install multi-pin connector:
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Note

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Insert multi-pin connector so that the locking pins -2- face towards
es, in part or in w

t to the co
the locking slide -1-.

– Insert multi-pin connector into respective slot to stop so that

rrectness of i
locking pin -2- is inserted into cut-out -4- and press inwards
until locking lug -3- engages.
l purpos

– Press locking slide -1- to stop -arrow-; possible only if all multi-
pin connectors are inserted until locking lugs -3- are engaged.

nform
mercia

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or

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ate

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for

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Prote AG.

1. Relay plate 233

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

2 Wiring harness and connector re‐

pairs

2.1 Safety remarks:

WARNING

♦ Airbag and seat belt tensioner

en AG. V
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lkswafail.
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♦ Faulty repairs to by the airbag and seat belt tensioning
Vol
k not
gu sys‐
ara
tem can cause
rise malfunctions in the passenger protection
d
nte
system.autho eo
ra
ss c
♦ For repair work on airbag and seat belt tensioner wiring

ce
le
un

harnesses, only contacts, connectors and wiring designed

pt
an
d

specifically for this purpose may be used ⇒ Parts cata‐

itte

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rm

logue!

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h re
♦ Observe country-specific regulations.
hole

spec
es, in part or in w

♦ Observe vehicle stickers indicating high voltage components.

t to the co
Before carrying out repairs, discharge residual voltage ⇒
General body repairs, interior; Rep. Gr. 69 .
rrectness of i
♦ Wires for airbag and belt tensioner wiring harness must only
be repaired using wiring harness repair set -VAS 1978- ⇒ In‐
l purpos

struction manual for wiring harness repair set -VAS 1978- .

2.2 General notes concerning repairs to ve‐

nform
ercia

hicle electrical system

m

a
com

tion in
r
te o

Caution
thi
s
iva

do
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To disconnect and connect the battery, the procedure descri‐

um
fo

en

bed in the workshop manual should be strictly adhered to

ng

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⇒ page 29 . t. Cop py
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♦ Observe current notes (also notes concerning removing and
agen
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installing components) in workshop manuals and in the Tech‐
nical Service Handbook.
♦ Yellow wiring and sections of wiring harness wrapped in yellow
tape indicate a prior repair ⇒ Operating instruction for wiring
harness repair set -VAS 1978- .
♦ Before beginning repairs to a wiring harness, first rectify the
cause of the damage, e.g. sharp edges on a body part, de‐
fective electrical consumer, corrosion.
♦ Disconnecting the battery earth strap (open circuit) provides a
safe working environment for repairs to the electrical system.
The battery positive wire need only be disconnected for re‐
moval of the battery.
♦ If possible, do not loosen any earth wires from the body (dan‐
ger of corrosion).

2.3 Remarks concerning wiring harness and

connector repairs
Supplementary notes on repair of CAN bus wiring ⇒ page 235 .
♦ Soldering is not permitted for repairs to vehicle wiring.

234 Rep. Gr.97 - Wiring

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

♦ Never repair any heat-shrink connections. If necessary, lay

wiring parallel to the defective wiring.
♦ Onboard supply wiring harnesses and connectors may only
be repaired using wiring harness repair set -VAS 1978- ⇒
Operating instructions for wiring harness repair set -VAS
1978- .
♦ Perform wiring harness repairs only with yellow wires. Mark
repair locations with yellow tape.
♦ Shielded wires must not be repaired. In case of damage, they
must be entirely replaced.

2.4 Supplementary notes on repair of CAN

bus wiring
♦ An unshielded two-wire line -1- and -2- with a cross section of
0.35 mm2 or 0.5 mm2 is used for CAN bus wiring.
♦ The colour codes of the CAN bus wiring can be gleaned from
the following table:
Drive train CAN, high orange/black
Convenience CAN, high orange/green
Infotainment CAN, high orange/violet
CAN low wire, (all) orange/brown
♦ Perform wiring harness repairs only with yellow wires. Mark
repair locations with yellow tape.
♦ When repairs are performed, both bus wires must have the
same length. When wires -1- and -2-
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twist spacing should be A=20
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♦ No section of wiringhorgreater
is than B=50 mm, e.g. in the vicinity ntee
of heat-shrink sleeves
sa
ut
-arrow-, should not be twisted. or
ac
s
ce
le
un

pt

2.5 Wiring harness repair set -VAS 1978-

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es, in part or in w

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tion in
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te o

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2. Wiring harness and connector repairs 235

 Transporter 1991 ➤ , Transporter 1996 ➤
AG. Volkswagen AG d
Electrical system - Edition 10.2004 agen oes
olksw not
V y gu
db ara
- Repairs to wiring harnesses rise nte
tho eo
and connectors of the onboard s au ra
c
electrical supply system s

ce
e
should only be carried out us‐

nl

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an
ing wiring harness repair set -

itte

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VAS 1978- .

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- Included with the wiring har‐

wit
, is n
ness repair set -VAS 1978- is

h re
a set of operating instructions, hole

spec
which provides comprehen‐
es, in part or in w

sive information on how to con‐

t to the co
duct repairs.
- Further information, e.g. re‐

rrectness of i
moval and installation of parts
and components, appears in
l purpos

the relevant workshop manual.

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mercia

at
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ion
c

in t
or

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ate

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cum
for

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236 Rep. Gr.97 - Wiring

 n AG. Volkswagen AG do
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d ran
tee Transporter 1991 ➤ , Transporter 1996 ➤
o
auth or
ac Electrical system - Edition 10.2004
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3 Renewal of aerial wiring

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A new repair concept has been developed for repair work on aer‐

ility
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ial wires. Now connecting wires in different lengths and various

wit
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adapter cables are available as replacement parts instead of a

h re
hole

complete aerial wire.

spec
es, in part or in w

3.1 General description

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♦ Aerial wires must not be repaired, but if repair is required, they
must be replaced only by connecting wires and adapter cables

rrectness of i
offered as genuine parts.
l purpos

♦ Replacement parts can be found in the electronic parts cata‐

logue (EKTA): Special catalogue; Electrical connections; Gen‐

nf
ercia

uine accessories; Subgroup 35 from illustration No. 035-20.

orm
m

atio
♦ These genuine parts are suitable for all aerial wires and wire
om

diameters which may need to be replaced.

n in
or c

thi
e

♦ No provision has been made for replacement of individual

t

sd
iva

aerial connectors in the event of repair.

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♦ The wires can be used retroactively for all VW models, with all
t.
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installed aerial wire diameters. Cop py
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♦ All adapter and connection wires are suitable for all transmitter
p by
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and receiver signals.
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Prote AG.
♦ This repair method can also be used for testing or retrofitting.

3.2 Assembly overview - an aerial wire

Example: Aerial wire between radio and aerial is defective. The
following wires are required for the repair:
1- Adapter cable, for connection to radio, length approx. 30 cm.
2- Connecting wire, available in different lengths.
3- Adapter cable, for connection to aerial, length approx. 30
cm.

3.3 Installing a new aerial wire

Note

Note that the total length of an aerial wire, depending on vehicle

equipment level, can be divided into sections by aerial diversity
control unit, traffic information control unit or aerial amplifier. Only
the defective section of aerial wire must be replaced.

– Pull defective aerial wire connections off units.

– Determine the routing of the defective aerial wire in vehicle
and measure the total length of the aerial connecting wire to
be replaced.

3. Renewal of aerial wiring 237

 Transporter 1991 ➤ , Transporter 1996 ➤
Electrical system - Edition 10.2004

The total length of aerial connecting wire is the sum of the length
of adapter cables required -1- and -3- and the connecting wire
-2-.
– To determine the length of connecting wire required, subtract
60 cm from the measured total length of aerial connecting wire
-2-.
– Procure the required adapter cables -1- and -3- and connect‐
ing wire -2- at length calculated as genuine part from the parts
catalogue.
– Cut off connectors of defective aerial wire.
The remainder of the defective aerial wire remains in the vehicle.
– Connect adapter cables -1- and -3- to equipment in vehicle.
– Route and secure connecting wire -2- parallel to the old aerial
wire.

Note

Do not kink or excessively bend aerial wires! The bending radius

must not be below 50 mm.

– Connect connecting wire to adapter cables.

n AG. Volkswagen AG do
wage
– Perform a functional check. yV
olks es n
ot g
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d
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ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

238 Rep. Gr.97 - Wiring