Volkswagen California 2010 Service Training Download Page 42 | Manualshive

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J519

J533

a

J285

b

c

d

J503

J255

R78

T16

R12

J772

J656

J345

J162

J412

J558

J731

R215

J362

J702

Electrics

The networking concept

What the abbreviations mean

E265 Rear climate control unit
E313 Selector lever
G24

Tachograph

G85 Steering

angle

sender

G303 Interior monitor send and receive module 1
G305 Interior monitor send and receive module 2
G384 Vehicle inclination sender
G397 Rain and light sensor
G419 ESP sensor unit
H12

Anti-theft alarm horn

J104

ABS control unit

J162

Water heater control unit

J234 Airbag control unit
J255 Climatronic control unit
J285 Control unit in dash panel insert
J345 Trailer detector control unit
J362 Immobiliser control unit
J364 Auxiliary air heater control unit

J386 Driver door control unit
J387

Front passenger door control unit

J412

Mobile telephone operating electronics control
unit

J446 Parking aid control unit
J492 Four-wheel drive control unit
J503 Control unit with display for radio and

navigation

J519

Onboard supply control unit

J527 Steering column electronics control unit in

steering wheel

J533 Data bus diagnostic interface
J558 Left sliding door control unit
J623 Engine control unit
J656 Voice amplification control unit
J702 Roof display unit
J772

Reversing camera system control unit

J731

Right sliding door control unit

J743

Mechatronic unit for dual clutch gearbox

J769 Lane change assist control unit
J770 Lane change assist control unit 2
J788 Isolator relay for CAN data bus drive
R12

Amplifier

R78

TV tuner

R215 Interface for external multimedia devices
T16

Diagnostic connection

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Summary of Contents for California 2010

Page 1: ...Service Training Self Study Programme 453 For the T5 2010 Commercial Vehicles ...

Page 2: ...m Volkswagen Commercial Vehicles The T5 from Volkswagen Commercial Vehicles Series production of the first Volkswagen Transporter started in March 1950 An initial production of 10 vehicles per day quickly developed into one of the most successful careers for an automobile and one which laid the foundation for a new vehicle segment Multivan and Caravelle also founded a new vehicle segment in which ...

Page 3: ...he brake system 30 The steering 34 Heating and air conditioning 38 The climate control 38 The auxiliary heaters 39 Electrics 40 The installation locations of the control units 40 The networking concept 42 The onboard supply control unit J519 44 The lights 46 The lane change assist 50 The reversing camera system 51 The dash panel 52 The media device interface box 53 Radio phone and navigation 54 Th...

Page 4: ...ia Introduction Overview of the most important highlights new TDI engines with common rail injection system 7 speed dual clutch gearbox 4MOTION with dual clutch gearbox and Servotronic Multivan now also with long wheelbase new driver assistance systems new infotainment programme and new air conditioning controls new fresh design in the interior e g new instrument clusters new fabrics and steering ...

Page 5: ...tly implements the new design language of Volkswagen The design revisions consistently support the character properties of the new T5 2010 Panel van window van and platform van with robust and solid grey grained front and rear bumpers corresponding to the type of vehicle Multivan Caravelle and California with painted front and rear bumpers this underlines the clear high quality character A clear f...

Page 6: ...van Double cab Platform van Single cab The pictures only show selected variants and their dimensions dimension ranges e g with short and long wheelbase etc the chassis is not shown here Please refer to the current sales literature for the complete set of technical data for the model range ...

Page 7: ...010 the Multivan will also be available with a long wheelbase The pictures only show selected variants and their dimensions dimension ranges e g short and long wheelbase normal roof medium high roof and high roof depending on the versions etc Please refer to the current sales literature for the complete set of technical data for the model range ...

Page 8: ...del The front end is new it has been adapted to the current face of the Volkswagen family and is the same for the Multivan and commercial vehicles The engine cover and the exterior mirrors have been improved in terms of their aerodynamics and reduced wind noise Acoustic glazing is also available as an option Front end The front end is composed of the following main components Assembly mount Bumper...

Page 9: ...y The cooling power is adapted to the equipment level by means of three different fan powers 450 W 600 W 850 W Assembly mount Ventilator Radiator Intercooler for TDI engine Bumper mount Bulkhead Cooler for power steering Condenser The attachments for all components on the assembly mount have changed Please always refer to the information in the workshop manual ...

Page 10: ...t riveting This involves the steel insert being pushed onto the extruded projections of the plastic part and then riveted by compression under the effect of heat All other parts of the assembly mount are made entirely of plastic Steel insert of the assembly mount hot riveted with assembly mount Bumper mount Chassis rail It is essential to comply with the information in the workshop manual with reg...

Page 11: ...tailgate then it is possible to open the tailgate from the inside The emergency unlocking function is installed on the tailgate above the tailgate lock behind a plastic cover The cover cap is identified with the opened tailgate symbol After the cover cap has been removed the emergency unlocking function can be actuated manually by pressing the lever for the emergency unlocking function Also refer ...

Page 12: ... switch to deactivate front passenger side airbag E224 Module Side airbag Front passenger Head thorax airbag Front passenger Module Head thorax airbag Front passenger In the commercial vehicle variants the belts at each of the outboard positions are integrated in the body and those for the middle seat positions are integrated in the seat Module Head thorax airbag Driver Front passenger airbag deac...

Page 13: ...eat belt with rack type belt tensioner attached to body Crash sensor in C pillar at bottom Head thorax airbag Driver ISOFIX child seat restraint systems are installed in the Multivan in the individual seats and in the commercial vehicles the outboard seats in the 1st row of the passenger compartment Crash sensor in B pillar at bottom Head thorax airbag As a new feature head thorax airbags are now ...

Page 14: ...boxes are concerned there are 2 manual gearboxes and one automatic The engine gearbox combinations Engine 5 speed manual gearbox 02Z 6 speed manual gearbox 0A5 DSG automatic gearbox 0BT 2 0 l 85 kW petrol engine AXA 2 0 l 62 kW TDI engine CAAA 2 0 75 kW TDI engine CAAB 2 0 l 103 kW TDI engine CAAC CCHA 2 0 l 132 kW TDI engine CFCA ...

Page 15: ...rpm Torque Nm Power kW Technical data Torque and power diagram Engine identification letter AXA Cubic capacity 1984 cm3 Design 4 cylinder inline engine Valves per cylinder 2 Bore 82 5 mm Stroke 92 8 mm Compression ratio 10 3 1 Max power 85 kW at 5200 rpm Max torque 170 Nm at 2700 rpm up to 4700 rpm Engine management BOSCH Motronic ME 7 5 Fuel Super unleaded with ROZ 98 Exhaust post treatment Pre a...

Page 16: ...c intake manifold VTG turbocharger Technical data Torque and power diagram Engine speed rpm Torque Nm Power kW Engine Engine identification letter CAAA Cubic capacity 1968 cm3 Design 4 cylinder in line engine Valves per cylinder 4 Bore 81 0 mm Stroke 95 5 mm Compression ratio 16 5 1 Max power 62 kW at 3500 rpm Max torque 220 Nm at 1250 rpm up to 2500 rpm Engine management EDC 17CP 20 Fuel Diesel a...

Page 17: ...VTG turbocharger Torque and power diagram Engine speed rpm Torque Nm Power kW Engine identification letter CAAB Cubic capacity 1968 cm3 Design 4 cylinder in line engine Valves per cylinder 4 Bore 81 0 mm Stroke 95 5 mm Compression ratio 16 5 1 Max power 75 kW at 3500 rpm Max torque 250 Nm at 1500 rpm up to 2500 rpm Engine management EDC 17CP 20 Fuel Diesel acc to DIN EN 590 Turbocharger VTG turboc...

Page 18: ...Technical data Torque and power diagram Engine speed rpm Torque Nm Power kW Engine Engine identification letter CAAC Transporter version CCHA Multivan Caravelle Cubic capacity 1968 cm3 Design 4 cylinder in line engine Valves per cylinder 4 Bore 81 0 mm Stroke 95 5 mm Compression ratio 16 5 1 Max power 103 kW at 3500 rpm Max torque 340 Nm at 1750 rpm up to 2500 rpm Engine management EDC 17CP 20 Fue...

Page 19: ... block with additional cooling ducts Piston with cooled ring groove Technical data Torque and power diagram Engine speed rpm Torque Nm Power kW Engine identification letter CFCA Cubic capacity 1968 cm3 Design 4 cylinder in line engine Valves per cylinder 4 Bore 81 0 mm Stroke 95 5 mm Compression ratio 16 5 1 Max power 132 kW at 4000 rpm Max torque 400 Nm at 1500 rpm up to 2250 rpm Engine managemen...

Page 20: ... of 250 Nm 6 speed manual gearbox 0A5 The 6 speed gearbox is also familiar from the previous model and is used in the 4 cylinder TDI engines with 103 132 kW It can transmit torques up to a maximum of 500 Nm The compact design is convenient for transverse installation and has been achieved by structuring it as a 4 shaft gearbox In the 4 shaft concept the pinion shafts are permanently engaged with t...

Page 21: ...ntributes to a further expansion in the technological lead enjoyed by Volkswagen For further information about this gearbox and its selector mechanism refer to self study programme no 454 The 7 speed dual clutch gearbox 0BT Advantages of the 7 speed DSG at a glance Reductions in fuel consumption and CO2 emissions Expansion and further development of expertise relevant for the competition in dual c...

Page 22: ...ising a dog clutch on the rear axle box The picture shows the four wheel drive system as an example in conjunction with a dual clutch gearbox The four wheel drive In the T5 2010 four wheel drive is available in all vehicle variants in conjunction with the 2 0 l 103 132 kW TDI engines It can be used with the 6 speed manual gearbox 0A5 and now for the first time also in conjunction with an automatic...

Page 23: ...ive Propshaft Bevel drive The bevel drive has been adapted for the higher torque requirements in the T5 2010 Two different bevel drives are used one of which is adapted for mounting on the manual gearbox and the other for the dual clutch gearbox ...

Page 24: ...onto the intermediate shaft with hypoid gearing and subsequently to the propshaft via the pinion The stub shaft for the right front wheel runs inside the hollow shaft This stub shaft is driven by the shaft bevel gear of the differential Front axle differential Powerflow Haldex coupling final drive to wheel front right to rear final drive Stub shaft for right front wheel Hollow shaft spur gear The ...

Page 25: ...ferential lock Output flange left Haldex coupling Mounting frame Four wheel drive control unit J492 Reservoir Haldex oil metal Drive flange Ventilation Haldex coupling Ventilation Rear axle box Rear axle box More information about the Haldex 4th generation coupling is available in self study programme no 414 4MOTION with generation IV 4WD coupling When service work is carried out on the rear axle ...

Page 26: ...e oil circuits from one another There is a spacer between the two halves of the double oil seal in order to guarantee that there will be a narrow gap The gap is connected to the atmosphere by means of a breather hole in order to equalise the pressure In the event of a leak of the pinion it is possible for leaking Haldex or final drive oil to reach the outside via the breather hole The double oil s...

Page 27: ...ntrol unit J492 Multi disc pack of the Haldex coupling Oil space Haldex oil Oil space final drive oil Pump for Haldex coupling V181 Double oil seal Pinion Drive from propshaft Double oil seal Torsional vibration damper Breather hole ...

Page 28: ...ning gear have undergone further development This means it satisfies the demands of driving even more effectively Revised ESP generation with extended range of functions Brake light switch and sender for clutch position in revised version The front axle design is adopted from the Transporter 2004 Servotronic steering with speed dependent control Adjustable steering booster pump ...

Page 29: ...picture corresponds to front wheel drive The rear axle design is adopted from the Transporter 2004 New 17 inch dual piston brake on the front axle Four wheel drive now also with the new 7 speed dual clutch gearbox 0BT ...

Page 30: ...e the latest generation of ESP electronic stabilisation programme This is a further contribution towards the continuous process of meeting the safety targets set by Volkswagen Commercial Vehicles The ESP system is not available at present in back to back cabs T5 cabs intended for subsequent completion e g as a mobile home vehicle transporter or for manufacturing special vehicles ESP control unit c...

Page 31: ...ce Fading brake support If fading is detected reduction in brake effectiveness when brakes are hot then the brake pressure is increased using the ABS pump thereby improving the braking effect Hydraulic brake assistant The pneumatic brake assistant is replaced by a hydraulic brake assistant in the T5 2010 The brake assistant is activated when the driver presses the brake pedal quickly but not power...

Page 32: ...e than 3000 kg are equipped with new revised 17 inch brakes on the front axle as standard The 17 inch brake is optional for all other engines The larger brake disc combined with the increase in pad contact area improved pad pressure by a double piston calliper and more rigid housing thanks to the frame calliper principle mean that the braking effect is significantly improved thereby increasing the...

Page 33: ...both Hall sensors are sent to the engine control unit The brake light switch can be renewed individually Clutch position sender Exclusively in the 132 kW engine version a sender positioned on the clutch master cylinder is used for establishing the clutch position Two Hall sensors installed in the clutch position sender register when the clutch is actuated and also when the clutch pedal has been fu...

Page 34: ...hicles and is an option for all other T5 2010 models It is a feature of Servotronic that the steering support is reduced as the vehicle speed increases This increases driving safety Steering booster pump Steering box Steering column Power steering hydraulic pressure valve N315 More details about Servotronic is available in self study programme no 277 The Phaeton running gear ...

Page 35: ... disc allowing the vanes to be adjusted The delivery rate can be varied by the different positions of the vanes Steering booster pump Input from servo oil tank Pressurised oil to steering box output Control piston Cam disc Stroke adjustment activation on both sides Rotor Vanes 11 pieces Outer ring The adjustment enables the pressure of the hydraulic pump to be adapted to the engine speed thereby e...

Page 36: ...pump pressure acts on one side of the control piston and moves this to the left against the spring force as the pressure increases In a defined medium rotation speed range the ducts to the chambers between the outer ring and cam ring left and right chambers are closed by the control piston This equalises the pressure between the two chambers The cam ring is held in a defined central position the d...

Page 37: ...ed to the suction line The opposite right chamber has pump pressure applied to it The cam ring is pushed to the left against the spring force the eccentricity between the rotor and the cam ring is reduced The delivery volume is reduced thereby preventing overproduction of pressurised oil The associated reduction in power consumption by the pump means that energy consumption is reduced significantl...

Page 38: ... AUTO Low mode is a mode with small air quantities Acoustic comfort takes precedence The temperature control is less abrupt the fresh air blower speed is lower than in AUTO High mode Side nozzles in comfort headlining The T5 2010 with comfort headlining not only has nozzles for air conditioning the compartment air but also special side nozzles located further out from the normal nozzles These side...

Page 39: ...04 The advantages of the Airtronic D3 B3 Plus are More compact dimensions Lower weight Optimised and more precise control of the heating power levels Operating and display unit The auxiliary heaters are operated by the operating and display unit for the auxiliary heater E407 in the roof in the California the auxiliary heater is operated using the operating and display unit for camping equipment E1...

Page 40: ...ics Control unit for left door Engine control unit MDI control unit UHV control unit Airbag control unit Amplifier and TV tuner Control unit for right door Remote control receiver for auxiliary heating Control unit for parking aid Onboard supply control unit ...

Page 41: ...assist left Control unit for lane change assist right Control unit for reversing camera Control unit for right sliding door Left sliding door control unit Control unit for voice amplification and CD changer Control unit for trailer detection ...

Page 42: ...iliary air heater control unit J386 Driver door control unit J387 Front passenger door control unit J412 Mobile telephone operating electronics control unit J446 Parking aid control unit J492 Four wheel drive control unit J503 Control unit with display for radio and navigation J519 Onboard supply control unit J527 Steering column electronics control unit in steering wheel J533 Data bus diagnostic ...

Page 43: ...527 G305 G397 E265 J364 CAN data bus driveline CAN data bus comfort infotainment CAN data bus sensor LIN data bus CAN data bus line LIN data bus line Data line Control line K line a CAN data bus diagnosis b LIN data bus door c LIN data bus roof d LIN data bus local interconnect network only for 2 0 l petrol engine ...

Page 44: ...uctor switches The particular bulb function is switched via one pin each in this case e g all the turn signals on one side Bulb monitoring has been implemented for the bulbs switched by the onboard supply control unit Onboard supply control unit J519 New onboard supply control unit J519 Convenience system central control unit J393 Depending on the control unit variant the J519 controls at least th...

Page 45: ...r interlock Reversing light control DQ500 only Cruise control system Fog light static turning light control LIN data bus anti theft alarm alarm horn Lights Enable read in main beam light flash Automatic running light coming home leaving home Low beam number plate light daytime running light control Rear fog light control Reversing light control Additional variant for radio remote control 315 MHz I...

Page 46: ...ight model according to the model and equipment If there are no daytime running lights then only the 55 W coiled filament of the H15 bulb is used Headlight module H4 The T5 2010 is equipped with an H4 headlight model according to the model and equipment If there are no daytime running lights then the bulb for the daytime running lights is still fitted but it cannot be used Dipped beam H7 55 W Side...

Page 47: ...cture and the resulting distribution of the illuminated surfaces All other model variants of the T5 2010 retain the tail light familiar from the Multivan 2004 which is installed together with the H4 headlight module Turn signal PY 21 W Reversing light P 21 W Rear fog light P 21 W Tail light R 10 W Brake and tail lights P 21 5 W Brake light P 21 W Reversing light P 21 W Turn signal PY 21 W Rear fog...

Page 48: ...en the vehicle is braked in a dangerous situation the brake lights flash with high frequency as a warning to the traffic behind Emergency warning flash If the speed drops below 10 km h in this emergency braking situation then the brake lights stop flashing and reverts to a steady light for as long as the brake pedal is still being pressed The hazard warning lights are switched on The hazard warnin...

Page 49: ...urning request The turn indicator signal has a greater priority than the steering angle in this case For example if the onboard supply control unit receives the information turn indicator left and steering wheel angle right then the direction of the indicators applies At speeds up to 40 km h the side of the road on the inside of the bend is illuminated by the fog light when the vehicle is turning ...

Page 50: ...ed of 30 km h or more The lane change assist warning lamp in the right hand round instrument of the dash panel insert indicates whether the system is active or passive Functions of warning lamp not lit system is switched off or there is an error yellow system switched on and passive green system switched on and active For information about the lane change assist refer to self study programme no 39...

Page 51: ...colour display of the navigation system without distortion and with superimposed dynamic and static assistance lines The reversing camera system As an extension to the previous ultrasound based system for assistance during parking the T5 2010 with tailgate can be equipped with the option of a reversing camera system Installation position of system components Reversing camera Control unit for rever...

Page 52: ... versions of the dash panel are installed Some models like the Caravelle and platform vans have the dash panel shown adjacent The middle section of the dash panel only has a narrow downwardly tapering housing contour for accommodating the joystick control Other models such as the Multivan Highline feature the following dash panel This dash panel version is extended downwards in the centre part acr...

Page 53: ...ng on the vehicle equipment Detailed information about the media device interface box can be found in self study programme no 423 The Golf 2009 Medium Premium Gearshift recommendation Depending on the equipment the T5 2010 has a display in the multifunction indicator of the dash panel insert in order to provide a recommendation for the driver to change gear in order to drive more economically Arro...

Page 54: ...sing camera Loudspeaker output stages with 20 watt output 2 or 4 loudspeakers can be connected Treble bass and balance adjustment Fader setting only with four loudspeakers Speed dependent volume adjustment Brightness of display lighting can be controlled independently from lighting inside vehicle Self diagnosis and loudspeaker diagnosis Service test mode Navigation function with map integrated dri...

Page 55: ...els 6 5 inch 800 x 480 pixels depending on equipment DVD player CD MP3 and WMA audio data CD MP3 and WMA audio data navigation data CD MP3 and WMA audio and DVD video data navigation data Map view 3D Map view 2D and 3D No 417 No 423 No 423 S453_058 S453_060 S453_059 ...

Page 56: ...or AM FM TV aerials are each located together on one aerial foil with associated signal pathways The GSM aerial is located on a separate aerial foil Right exterior mirror The signal pathways of the FM2 or FM2 DAB or FM2 TV aerials are located on a shared aerial foil in each case The GPS aerial is attached to the interior housing of the exterior mirror Exploded view example of right exterior mirror...

Page 57: ... inside of the mirror housing Right exterior mirror The signal pathways of the FM2 or FM2 DAB aerials are located on a shared aerial foil in each case The GPS aerial is attached to the interior housing of the exterior mirror At the moment no TV aerial is provided FM2 or FM2 DAB Exploded view example of right exterior mirror Mirror housing Aerial foil Mirror base carrier GPS aerial Housing frame Ad...

Page 58: ...ot be renewed separately AM FM DAB and TV aerials are phantom powered The phantom supply approx 12 V is used for supplying power to the impedance converter and the diagnostic function GPS aerial The GPS aerial is secured with an adhesive pad The internal electronics are powered via the phantom supply 5 V GSM aerial In the GSM aerial the phantom supply 12 V is only required for the diagnostic capab...

Page 59: ... be dismantled without damaging it The aerial foils are attached in the exterior mirror by glue points GPS aerial The GPS aerial is located on a magnetic holder This is screwed onto the inside of the mirror housing All plug connections are mechanical and colour coded GSM aerial The GSM aerial is attached to the inside of the mirror housing by glue Exterior mirror left Exterior mirror right Regardi...

Page 60: ...sed in accordance with the vehicle equipment by installing an AM filter for all electrical connections to components that are located inside the exterior mirror exterior mirror heater adjustment etc The AM filter is part of the door cable kit The AM aerial is always located in the left exterior mirror therefore no filter is required on the right side Left exterior mirror AM FM aerial Right exterio...

Page 61: ...and UHV DAB Left exterior mirror AM FM aerial GSM aerial with UHV Right exterior mirror with DAB FM2 DAB aerial GPS aerial not used Right exterior mirror in equipment without DAB FM2 aerial Aerials radio RCD 210 and UHV Left exterior mirror AM FM aerial GSM aerial with UHV Right exterior mirror without aerials Aerial mount Aerial mount ...

Page 62: ...gation Left exterior mirror AM FM aerial GSM aerial with UHV Left exterior mirror AM FM TV aerial GSM aerial Right exterior mirror FM2 DAB aerial DAB aerial is not used GPS aerial Right exterior mirror FM2 TV aerial GPS aerial Aerials radio navigation unit RNS 310 and UHV Aerials radio navigation unit RNS 510 and UHV TV Aerial mount Aerial mount Aerial mount TV tuner ...

Page 63: ...Telephone microphone Key E440 Multifunction buttons in steering wheel left E441 Multifunction buttons in steering wheel right R38 Telephone microphone J285 Control unit in dash panel insert J412 Mobile telephone operating electronics control unit J503 Control unit with display for radio and navigation More detailed information about the UHV telephone preparations is available in self study program...

Page 64: ...ved Subject to technical modifications 000 2812 33 20 Technical status 11 2009 Volkswagen AG After Sales Qualifizierung Service Training VSQ 1 Brieffach 1995 D 38436 Wolfsburg Paper made from cellulose bleached without the use of chlorine 453 ...

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