Volkswagen up! 2012 Workshop Manual Download Page 3

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Contents

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

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

Assembly overview - battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2

Removing and installing battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3

Removing and installing earth wire with battery monitor control unit J367 . . . . . . . . . . . .

1.4

Adapting battery monitor control unit J367 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5

Disconnecting and connecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6

Removing and installing battery tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7

Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8

Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.1

Assembly overview - alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.2

Removing and installing alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.3

Checking alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.4

Checking poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.5

Removing and installing poly V-belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.6

Removing and installing voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.1

Assembly overview - starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.2

Removing and installing starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.3

Checking starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.1

General description - start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.2

Removing and installing voltage stabiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

90 - Gauges, instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.1

Assembly overview - dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.2

Removing and installing dash panel insert KX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.1

Assembly overview - horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.2

Removing and installing treble horn H2 and bass horn H7 . . . . . . . . . . . . . . . . . . . . . . . . 39

92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

windscreen wiper system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

1.1

Assembly overview - windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

1.2

Moving wipers to service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1.3

Removing and installing wiper blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1.4

Removing and installing wiper arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1.5

Adjusting wiper arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

1.6

Renewing windscreen wiper rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1.7

Removing and installing wiper motor V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

1.8

Renewing wiper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2.1

Assembly overview - windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2.2

Removing and installing washer fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.3

Removing and installing windscreen washer pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

2.4

Removing and installing spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.5

Adjusting spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Rear window wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3.1

Assembly overview - rear window wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

up! 2012 ➤

Electrical system - Edition 03.2017

Contents

Summary of Contents for up! 2012

Page 1: ...e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d...

Page 2: ...anual Repair Groups Repair Group 27 Starter current supply CCS 90 Gauges instruments 92 Windscreen wash wipe system 94 Lights bulbs switches exterior 96 Lights bulbs switches interior 97 Wiring Techni...

Page 3: ...r 24 3 1 Assembly overview starter 24 3 2 Removing and installing starter motor 25 3 3 Checking starter 27 4 Cruise control system CCS 28 5 Start stop system 29 5 1 General description start stop syst...

Page 4: ...r V48 V49 74 1 10 Removing and installing dipped beam bulb 75 1 11 Removing and installing bulb for daytime running light side light 77 2 Fog lights 79 2 1 Assembly overview fog lights 79 2 2 Removing...

Page 5: ...nd installing seat heater pushbutton 133 2 8 Removing and installing key operated switch to deactivate front passenger side airbag 133 2 9 Removing and installing operating unit for window regulator i...

Page 6: ...l e i s n o t p e r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r...

Page 7: ...battery page 5 1 6 Removing and installing battery tray page 8 1 7 Checking battery page 9 1 8 Charging battery page 9 1 1 Assembly overview battery Warning notices and safety regulations All the ins...

Page 8: ...for earth wire battery terminal clamp M6 Specified torque 6 Nm 3 Earth wire cover 4 electronics box with holder Removing and installing page 143 Specified torque for nut securing electronics box to b...

Page 9: ...tions page 1 Caution To disconnect and reconnect the battery the procedure de scribed in the workshop manual should be strictly adhered to page 5 Replacing battery on vehicles with start stop system B...

Page 10: ...ing by clamping bracket possible leakage of acid with high consequential costs Poor crash safety Install in the reverse order of removal observing the following Place battery 4 on battery tray 3 and p...

Page 11: ...following Adapt battery monitor control unit J367 page 5 Specified torques 1 1 Assembly overview battery page 1 1 4 Adapting battery monitor control unit J367 After the installation of a new starter...

Page 12: ...NING Risk of injury Comply with the warning notices and safety reg ulations page 1 Disconnecting battery Note By disconnecting the battery earth wire open circuit safety is ensured when carrying out w...

Page 13: ...the nut of battery terminal clamp for positive cable 1 and pull terminal clamp 2 off battery positive terminal Connecting battery Caution Comply with instructions regarding threaded connections of the...

Page 14: ...ery Tighten securing nut Work through steps listed in table Procedures after reconnecting battery Procedure Performed Ignition with ignition key switch on ignition and then switch off again Read event...

Page 15: ...rant line holder 5 and pull holder upwards off battery tray Lift battery tray 1 Disconnect connectors from engine control unit To do this press catch 1 with a screwdriver in direction of arrow Swing l...

Page 16: ...14 2 5 Removing and installing poly V belt pulley page 14 2 6 Removing and installing voltage regulator page 19 2 1 Assembly overview alternator 1 Protective cap 2 Nut for securing battery positive c...

Page 17: ...alternator natural gas engine page 12 2 2 1 Removing and installing alternator pet rol engine Caution To disconnect and reconnect the battery the procedure de scribed in the workshop manual should be...

Page 18: ...n When fitting used poly V belts take note of the direction of rotation as marked during removal Before installing poly V belt ensure that all ancillaries al ternator air conditioner compressor are se...

Page 19: ...ses Do NOT stretch kink or bend refrigerant lines and hoses Remove air conditioner compressor from bracket Heating air conditioning system Rep gr 87 Air conditioner com pressor Removing air conditione...

Page 20: ...Use a socket spanner to turn engine at vibration damper on pulley Check poly V belt for Sub surface cracks cracks core ruptures cross sectional breaks Layer separation top layer cord strands Base brea...

Page 21: ...t C o p y r i g h t b y V o l k s w a g e n A G Socket VAS 3310 Torque wrench V A G 1332 Removing Remove alternator page 10 Clamp alternator in a vice at securing points Use socket VAS 3310 to unscre...

Page 22: ...at securing points Remove protective cap where there is one from poly V belt pulley with freewheel Insert multipoint adapter T10474 1 into poly V belt pulley and fit an open end spanner width across...

Page 23: ...ng direction of torque wrench to anti clockwise at socket drive First screw poly V belt pulley with freewheel onto alternator shaft by hand as far as possible Insert multipoint adapter T10474 1 into p...

Page 24: ...17 mm to it Insert hexagon socket or TORX socket 2 into alternator shaft Turn generator shaft clockwise left handed thread to loosen it counterholding it with the open end spanner Hold poly V belt pul...

Page 25: ...r shaft Turn alternator shaft anti clockwise using torque wrench V A G 1332 3 in order to tighten poly V belt pulley with freewheel Specified torques 2 1 Assembly overview alternator page 10 2 6 Remov...

Page 26: ...g bolt and nuts arrows and remove deflector cap from alternator Unscrew securing bolts of voltage regulator arrows Remove voltage regulator from alternator Installing Install in the reverse order of r...

Page 27: ...Torque screwdriver V A G 1624 Removing Remove alternator C page 11 Using offset screwdriver for slotted head screws VAS 6416 carefully lever off protective cap 1 at fasteners arrows Unscrew securing...

Page 28: ...a g e n A G Torque wrench V A G 1783 Removing Remove alternator page 11 Remove clamping rings arrows and remove protective cap from alternator Unscrew securing bolts of voltage regulator arrows Remove...

Page 29: ...rac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Push prote...

Page 30: ...o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 Starter motor 3 1 Assembly overview starter page 24 3 2 Removing and installing starter motor page 25 3 3 Checking starter page 27 3 1 As...

Page 31: ...hicles with start stop system Due to the higher requirements on the starter when the start stop system is activated e g in urban traffic driving the deep cycle resistance has been increased and the ri...

Page 32: ...installing starter auto mated manual gearbox Renewing starter on vehicles with start stop system Due to the higher requirements on the starter when the start stop system is activated e g in urban traf...

Page 33: ...o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew starter securing bolts 2 Remove starter 1 by taking it upwards out of t...

Page 34: ...c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 Cruise control system CCS All the instructions and information for this manual are fou...

Page 35: ...the battery data are not registered by the sensor while charging Then the values concerning the battery state and saved in the data bus diagnostic interface would not correspond to the values of the c...

Page 36: ...n trol unit If radio radio navigation and telephone units have failed together first check fuse of voltage stabiliser 5 2 Removing and installing voltage stabil iser Removing Push driver s seat as far...

Page 37: ...ert 1 1 Assembly overview dash panel insert page 31 1 2 Removing and installing dash panel insert KX2 page 36 1 1 Assembly overview dash panel insert 1 1 1 Assembly overview dash panel insert indicato...

Page 38: ...i g h t b y V o l k s w a g e n A G 1 Indicator lamp for left turn signal Switched on 2 Electronic stabilisation pro gramme ESP warning lamp Flashes electronic sta bilisation programme ESP regulating...

Page 39: ...nual gearbox 12 Coolant temperature warning lamp Coolant temperature too high or Engine coolant level too low 13 Oil pressure warning lamp Oil pressure too low Switch off engine and check oil level 14...

Page 40: ...belt ten sioner defective 5 Seat belt warning lamp Fasten seat belts 6 Indicator lamp for traction control Flashes regulating Lights up faulty or switched off by system 7 Indicator lamp for tyre pres...

Page 41: ...fault in brake system Lights up brake fluid low stop engine and check brake fluid level 22 Indicator lamp for automated manual gearbox Flashes vehicle is not secured against rolling away 23 Indicator...

Page 42: ...ped with light emitting diodes Light emitting diodes cannot be re newed separately if defective The dash panel insert must be renewed The dash panel insert KX2 must not be dismantled It is not necessa...

Page 43: ...e films 1 on left and right into gap arrows be tween dash panel insert and dash panel cowling If the pro tective film is not used the dash panel cowling and the edge of the dash panel will be scratche...

Page 44: ...e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 Horn 2 1 Assembly overview horn page 38 2 2 Removing and installing treble...

Page 45: ...s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 2 Removing and installing treble horn H2 and bass horn H7 Removing Unscrew bolt 1 Remove bracket...

Page 46: ...s page 42 1 5 Adjusting wiper arms page 44 1 6 Renewing windscreen wiper rubber page 46 1 7 Removing and installing wiper motor V page 47 1 8 Renewing wiper motor page 49 1 1 Assembly overview windscr...

Page 47: ...tch is operated or when road speed exceeds 6 km h Caution Risk of damage to wiper blades due to freezing In the event of frost check if wiper blades are frozen Note If it is necessary for the windscre...

Page 48: ...g Install in the reverse order of removal observing the following Caution Risk of damage to the vehicle body Wiper blades for driver and front passenger sides each have a different length Push wiper b...

Page 49: ...l k s w a g e n A G Note If it is necessary for the wiper motor to run during the working procedure the bonnet must be closed as otherwise the power supply to the wiper motor will be interrupted The r...

Page 50: ...shaft Turn thrust bolt 1 of puller clockwise using an Allen key 6 mm AF until wiper arm 4 is loosened off shaft Remove puller and wiper arm Repeat this process with the second wiper arm Installing Ins...

Page 51: ...ocedure is described for left hand drive vehicles Removal and installation for right hand drive ve hicles is similar Move wipers to park position and then switch off ignition Adjust windscreen wiper p...

Page 52: ...fied torques 1 1 Assembly overview windscreen wiper system page 40 1 6 Renewing windscreen wiper rubber Note Refer to chapter Distinguishing features of joint free wiper blades in Workshop manual Elec...

Page 53: ...y Fit windscreen wiper blade page 41 Check wiper blade is working correctly 1 7 Removing and installing wiper motor V Caution To disconnect and reconnect the battery the procedure de scribed in the wo...

Page 54: ...tch off ignition Disconnect battery page 5 Remove wiper arms page 42 Remove plenum chamber cover General body repairs ex terior Rep gr 50 Bulkhead Assembly overview plenum chamber cover Undo screws ar...

Page 55: ...arrows Push connector onto connection on wiper motor so that con nector latches into place Install plenum chamber cover General body repairs exte rior Rep gr 50 Bulkhead Assembly overview plenum chamb...

Page 56: ...Danger of becoming caught pinched in the rotating parts Do not hold wiper motor near rotating parts after it has been removed Operate wiper motor briefly until park position is reached Reconnect batte...

Page 57: ...p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Press ball head a...

Page 58: ...windscreen washer pump page 54 2 4 Removing and installing spray jets page 55 2 5 Adjusting spray jets page 56 2 1 Assembly overview windscreen washer system 1 Angled piece Connection to right windscr...

Page 59: ...curing reservoir to body 8 Nm 9 Windscreen and rear window washer pump V59 Removing and installing page 54 10 Angled connection piece Connection to windscreen and rear window washer pump V59 Overview...

Page 60: ...h connecting pipe and filler neck 1 from vehicle Installing Install in the reverse order of removal observing the following Guide connecting pipe clip together with filler neck 1 upwards through body...

Page 61: ...washer pump V59 2 up wards out of reservoir 5 Release and pull off connector 1 Note The connections to the pump and hose lines are colour coded in order to prevent the washer fluid lines being incorre...

Page 62: ...1 Fit hose connection 2 onto spray jet and lock hose clip 3 Starting at the top push spray jet into mounting hole until it locks in place audibly Adjusting spray jets page 56 2 5 Adjusting spray jets...

Page 63: ...ar window wiper system page 57 3 2 Removing and installing wiper blade page 58 3 3 Removing and installing wiper arm page 58 3 4 Adjusting wiper arm page 59 3 5 Removing and installing rear window wip...

Page 64: ...ing Caution Risk of damage to the wiper blade Joint free wipers are very flexible To lift the wiper blades off the rear window touch them only in the area in which the wiper blades are attached to the...

Page 65: ...tion Switch off ignition Withdraw ignition key Fold cover cap 1 of rear window wiper up and unclip it Loosen but do not completely remove securing nut arrow Fit puller T10369 5 to wiper arm 2 Fit thru...

Page 66: ...per system page 57 3 5 Removing and installing rear window wiper motor V12 Special tools and workshop equipment required Torque wrench V A G 1331 Removing Remove wiper arm page 58 Remove rear lid trim...

Page 67: ...ller pipe with filler neck for reservoir for windscreen wash er system Removing and installing page 53 2 Windscreen and rear win dow washer pump V59 Removing and installing page 54 3 Washer fluid rese...

Page 68: ...ws and pull spray jet 1 to rear out of high level brake light M25 Installing Install in reverse order of removal Adjusting spray jet page 62 4 3 Adjusting spray jet Note In case of uneven spray field...

Page 69: ...a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 5 Washer fluid lines 5 1 Repairi...

Page 70: ...oving and installing headlight page 66 1 3 Adjusting headlights page 67 1 4 Adjusting headlight installation position page 67 1 5 Removing and installing front turn signal bulb M5 M7 page 68 1 6 Insta...

Page 71: ...lb for left daytime running light L174 Right bulb which func tions as bulb for right side light M3 and bulb for right daytime running light L175 Bulb 12 V 21 5 W Removing and installing page 77 7 Bulb...

Page 72: ...2 Removing and installing headlight Special tools and workshop equipment required Torque wrench V A G 1331 Note It is not necessary to disconnect the battery earth wire The illustrations show removal...

Page 73: ...on position so that shut lines gaps around headlight are even If the shut lines gaps around the headlight are uneven the installation position must be adjusted page 67 Check functions of headlight Che...

Page 74: ...ling out alignment bush arrow on headlight Tighten bolts Check headlight installation position to ensure gaps are even correct if necessary Check functions of headlight Checking headlight settings and...

Page 75: ...h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Note The removal and installation procedure is described for the left hand side The removal and installation procedure for the righ...

Page 76: ...an fabric gloves when inserting bulbs Make sure the bulb holder is correctly seated when instal ling The ingress of water will cause permanent damage to the headlight Check functions of headlight Chec...

Page 77: ...sitive fit and tighten the two screws A Install headlight page 66 Check headlight settings and adjust if necessary Mainte nance Manual Maintenance Booklet 35 1 Descriptions of work Specified torques C...

Page 78: ...two screws A Install headlight page 66 Check headlight settings and adjust if necessary Mainte nance Manual Maintenance Booklet 35 1 Descriptions of work Specified torques Component Specified torque...

Page 79: ...rews A Install headlight page 66 Check headlight settings and adjust if necessary Mainte nance Manual Maintenance Booklet 35 1 Descriptions of work Specified torques Component Specified torque Securin...

Page 80: ...is being driven The asymmetrical dipped beam of the headlights in the up remains below the legally prescribed dazzle values even if the headlight lens is masked Converting the headlights temporarily f...

Page 81: ...Swing ball head of headlight range control motor 2 into mounting in headlight 1 from the right while pulling the re flector towards the rear Insert the actuator 3 into its mounting on headlight housin...

Page 82: ...d main beam Removing Switch off ignition and all electrical consumers and withdraw ignition key Release and pull off connector 4 Pull cover 5 off rear of headlight Release retaining clip 2 and pull it...

Page 83: ...rsting filament lamps and gas dis charge bulbs Remove filament bulbs and gas discharge bulbs carefully Always wear safety goggles and gloves when removing and installing filament bulbs or gas discharg...

Page 84: ...unning light 12V 21 5W Installing Install in the reverse order of removal observing the following Caution Risk of damage to the headlight Do not touch the glass part of the bulb with bare fingers Fing...

Page 85: ...fog lights page 79 2 2 Removing and installing fog light page 79 2 3 Removing and installing fog light bulb page 80 2 4 Adjusting fog lights page 81 2 1 Assembly overview fog lights 1 Securing bolts...

Page 86: ...e filling pipe of the washer fluid reservoir to one side a little in order to gain access to all the securing screws Undo screws arrows and remove fog light housing 2 from front bumper cover 3 Install...

Page 87: ...y attached to the bulb holder and cannot be renewed separately Fog light bulb HB4 12 V 51 W Installing Install in the reverse order of removal observing the following Caution Risk of damage to the hea...

Page 88: ...r the right hand side is basically the same Removing Switch off ignition and all electrical consumers and withdraw ignition key Caution Release of side turn signals is only possible in one direction G...

Page 89: ...using into body starting with the spring clip 2 press in direction of spring clip arrow and secure it in body with fixed anchor point 1 Following installation check whether turn signal light is func t...

Page 90: ...Removing and installing reversing light bulb page 88 4 8 Removing and installing turn signal bulb page 89 4 1 Assembly overview tail lights in body 1 Left tail light MX3 or right tail light MX4 in si...

Page 91: ...nd withdraw ignition key Remove tail light in side panel page 86 Push catches arrows outwards and remove bulb carrier 1 from tail light housing Installing Install in the reverse order of removal obser...

Page 92: ...o l k s w a g e n A G 4 4 Removing and installing tail light Note The removal and installation procedure is described for the left hand side The removal and installation procedure for the right hand...

Page 93: ...fitted the wiring har ness must be fed through the aperture to the inside without it getting trapped Screw on securing nut by hand as far as stop When installation is complete check gap shut lines to...

Page 94: ...draw ignition key Remove tail light bulb carrier in side panel page 85 Push bulb for brake light and tail light 1 into holder turn anti clockwise and pull upwards out of bulb carrier 6 Bulb for brake...

Page 95: ...k s w a g e n A G 4 8 Removing and installing turn signal bulb Note The removal and installation procedure is described for the left hand side The removal and installation procedure for the right han...

Page 96: ...nal brake light page 90 5 1 Removing and installing additional brake light Caution When removing and installing components that are in view switches covers trim and so on mask off areas in which tools...

Page 97: ...e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Insert assembly wedge T10039 1 1 at top between bulb for high level brake li...

Page 98: ...oups of 3 LEDs and are supplied with current in groups Due to the failure of individual LEDs the intact LEDs of the group in question are placed under increased strain and it must therefore be anticip...

Page 99: ...dge T10039 1 screwdriver are used to lever out those components using commercially available masking tape Removing Switch off ignition and all electrical consumers and withdraw ignition key Lever left...

Page 100: ...e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pull glass base bulb 2 in direction of arrow out of bul...

Page 101: ...ling airbag coil connector and return ring with slip ring F138 page 97 7 1 3 Removing and installing steering angle sender G85 page 98 7 1 4 Removing and installing ignition starter switch page 98 7 1...

Page 102: ...wing components feature self diagnosis capability Turn signal switch E2 Washer pump switch automatic wash wipe and headlight washer system E44 Cruise control system switch E45 Intermittent wiper switc...

Page 103: ...Installing Install in the reverse order of removal observing the following If the coil connector has been moved out of centre position accidentally the centre position can be redetermined by turn ing...

Page 104: ...8 page 97 7 1 4 Removing and installing ignition starter switch Removing Disconnect battery page 5 Remove steering column combination switch E595 page 95 Pull primary locking element 2 release connect...

Page 105: ...compatible systems Onboard power supply control unit J519 Electrical components Ignition starter switch 7 1 6 Removing and installing lock cylinder Removing Disconnect battery page 5 Remove steering...

Page 106: ...teering lock housing Installing Note For reasons of clarity the ignition key is not shown in the following illustration Insert ignition key in lock cylinder and turn to Drive position Using steel wire...

Page 107: ...ted without lock cylin der Special tools and workshop equipment required Angle hand drill Torque wrench V A G 1410 Removing Note To remove the steering lock housing the shear bolts must be drilled out...

Page 108: ...ay fly off and cause eye injury Wear safety goggles Undo screw 1 and remove cable Drill out shear head bolts arrows of steering lock housing 2 Note M8 bolts arrows core diameter 6 8 mm Pull steering l...

Page 109: ...nstalling airbag coil connector and return ring with slip ring F138 page 104 7 2 3 Removing and installing steering column combination switch E595 page 106 7 2 4 Removing and installing turn signal sw...

Page 110: ...r dual clutch gearbox Removing and installing page 114 3 Ignition key 4 Lock cylinder Removing and installing page 110 With immobiliser reader coil D2 Removing and installing immobiliser reader coil D...

Page 111: ...ng with slip ring G85 Note If the steering angle sender G85 is defective the airbag coil connector and return ring with slip ring F138 must be renewed Removing Remove lower steering column trim Genera...

Page 112: ...he airbag coil connector and return ring with slip ring F138 is always centred when delivered as a replacement part Do not change this setting Check the following before installing airbag coil connect...

Page 113: ...ft connector 2 from steering column combina tion switch E595 1 Disconnect right connector 2 from steering column combi nation switch E595 1 Push upper retaining tabs 2 on steering column combination s...

Page 114: ...E45 Cruise control system CCS SET button E227 Note If one of the components is defective the steering column com bination switch E595 must be renewed as a complete unit Sequence of operations Removing...

Page 115: ...22 Depending on vehicle equipment the following components are integrated into the steering column combination switch E595 as one unit Turn signal switch E2 Headlight dipper and flasher switch E4 Park...

Page 116: ...release ignition starter switch D Remove ignition starter switch D 1 from steering lock Installing Install in the reverse order of removal observing the following Note When installing the ignition sta...

Page 117: ...ing Remove lower steering column trim General body repairs interior Rep gr 68 Compartments and covers Removing and installing lower steering column trim WARNING Risk of damage to the electronic compon...

Page 118: ...lin der Note A seized steering lock must be renewed Installing Install in the reverse order of removal observing the following Note A new lock cylinder can be ordered from the responsible distri butio...

Page 119: ...me chanic must electrostatically discharge himself or herself by briefly grasping hold of door striker plate or similar Disconnect connector 2 on ignition starter switch D 1 Disconnect connector arrow...

Page 120: ...reverse order of removal observing the following Tighten new bolts arrows until shear heads break off 7 2 10 Removing and installing ignition key withdrawal lock solenoid N376 Removing Remove lower st...

Page 121: ...emoving and installing rear parking aid senders page 116 8 5 Removing and installing parking aid control unit J446 page 118 8 1 Assembly overview parking aid 1 Parking aid senders in rear bumper cover...

Page 122: ...ting volume and frequency of rear parking aid warning buzzer Adapting parking aid control unit J446 The volume and frequency of the rear parking aid system warning buzzer H15 can be adjusted by means...

Page 123: ...off ignition and all electrical consumers and withdraw ignition key Caution The order for removing the senders must be adhered to under all circumstances The sender may otherwise be damaged Fractures...

Page 124: ...installing the sender ensure that the isolation ring has been correctly fitted onto the sender head and does not ride or roll up on insertion into the sender retainer Both locking lugs of sender retai...

Page 125: ...i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Release and pull off connector 2 Undo th...

Page 126: ...deter mines that the driver does not brake sufficiently when faced with the threat of a collision the system can increase the braking force in order to reduce the speed for a possible collision In th...

Page 127: ...interior Rep gr 68 Interior mirror Assembly overview in terior mirror Release and pull off connector 1 Pull catch arrow and remove sensor unit for emergency braking function J939 2 from holder on wind...

Page 128: ...1 Removing and installing front passenger airbag warning lamp The front passenger side airbag deactivated warning lamp K145 is an integral part of the centre switch module in dash panel and cannot be...

Page 129: ...ading light in vehicles without panoramic sunroof page 123 1 4 2 Removing and installing front interior and reading light in vehicles with panoramic sunroof page 125 1 4 1 Removing and installing fron...

Page 130: ...he removal wedge VAS 3409 or a suitable screw driver carefully lever out the lens 1 at its catches arrows and remove it from the front interior light W1 2 Remove securing bolts 1 Release the locking l...

Page 131: ...and reading light contains the following compo nents Front interior light W1 Front passenger reading light W13 Driver side reading light W19 Sliding sunroof adjustment regulator EX4 page 139 Special t...

Page 132: ...h connectors 1 and 2 and then remove front interior and reading light Installing Installation is carried out in reverse order of removal 1 5 Removing and installing bulbs for front interior and readin...

Page 133: ...ation is carried out in reverse order of removal 1 5 2 Removing and installing bulbs for front interior and reading light in vehicles with panoramic sunroof Special tools and workshop equipment requir...

Page 134: ...in direction of arrow out of bulb holder 2 Bulb for front interior light W1 glass base bulb 12V 5W Installing Installation is carried out in reverse order of removal 1 6 Removing and installing front...

Page 135: ...e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Turn bulb holder 1 together with bulb of reading light in direction of arro...

Page 136: ...ling operating unit for window regulator in driver door E512 page 134 2 10 Removing and installing front window regulator switch page 135 2 11 Removing and installing mirror adjustment switch E43 E168...

Page 137: ...age compartments covers Assem bly overview dash panel cover on driver side Note For reasons of clarity the following illustration shows the installed headlight range control regulator E102 from the re...

Page 138: ...and installation is identical for both switch modules and is therefore described for one switch mod ule only Removing Switch off ignition and all electrical consumers and withdraw ignition key Remove...

Page 139: ...ule in middle of dash panel page 131 2 7 Removing and installing seat heater pushbutton The pushbutton for the seat heater on the right E654 and the pushbutton for the seat heater on the left E653 are...

Page 140: ...gr 68 Storage com partments covers Assembly overview dash panel cover on driver side Release and pull off connector 1 Press catches arrows on both sides and push the key oper ated switch for deactivat...

Page 141: ...in driver door E512 hav ing to be removed first When removing and installing components that are in view switches covers trim and so on mask off areas in which tools removal wedge VAS 3409 screwdrive...

Page 142: ...dow regulator switch E41 are carried out in the same way The operating unit for window regulator in driver door E40 must not be removed in order to remove the front left window regulator switch E512 R...

Page 143: ...l k s w a g e n A G Removal wedge VAS 3409 Removing Remove switch element on driver side page 134 Release the two catches arrows and push mirror adjustment switch E43 1 out of operating unit for wind...

Page 144: ...e console switch module The centre console switch module EX23 is located in the centre console in front of the gear lever and depending on the equip ment in the vehicle contains the following componen...

Page 145: ...t locks into place securely 2 14 Removing and installing pushbutton for emergency braking function The pushbutton for emergency braking function E773 is an in tegral part of centre console switch modu...

Page 146: ...r the immobiliser components via fax or tem porary access authorisation to the components is not availa ble All components associated with the immobiliser must be adap ted online All ignition keys inc...

Page 147: ...a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 2 Removing and insta...

Page 148: ...the workshop manual Electrical System General Information A link to this workshop manual is not possible at present for tech nical reasons Please select the workshop manual Electrical System General I...

Page 149: ...fuse holder behind dash panel on driver side page 147 1 1 Removing and installing electronics box E box Special tools and workshop equipment required Torque wrench V A G 1410 Caution To disconnect and...

Page 150: ...he connecting threads Unscrew nut arrow B Release the catches arrow C on each side of the electronics box holder and remove electronics Box together with holder upwards off the battery Turn the electr...

Page 151: ...side of the electronics box on the battery Special tools and workshop equipment required Torque wrench V A G 1410 Release tool set VAS 1978 35 Caution To disconnect and reconnect the battery the proce...

Page 152: ...om electronics box Turn electronics box over release locking lug arrow and pull fuse holder 1 upwards off the electronics box Press catches at sides arrows and remove lid of fuse holder 1 Make a note...

Page 153: ...s 6 Nm 1 3 Removing and installing relay and fuse holder behind dash panel on driver side 1 3 1 Removing and installing fuse holder behind dash panel on driver side page 147 1 3 2 Removing and install...

Page 154: ...in an RHD vehicle are analogous Removing Switch off ignition and all electrical consumers and withdraw ignition key Disconnect battery page 5 Insert removal wedge VAS 3409 or a screwdriver into open i...

Page 155: ...procedure de scribed in the workshop manual should be strictly adhered to page 5 Note The illustrations show removal and installation of the fuse car rier in an LHD vehicle Removal and installation o...

Page 156: ...ll fuses from the fuse carrier Pull primary locking elements 1 release all plug in contacts with the correct release tool from the release tool set VAS 1978 35 and then pull downwards out of the fuse...

Page 157: ...emoval and installation of the relay carrier in an LHD vehicle Removal and installation of the relay carrier in an RHD vehicle are analogous Removing Switch off ignition and all electrical consumers a...

Page 158: ...s into consideration Cut the cable tie arrow and unclip cable fuse 1 from relay carrier Make a note of the assignment of the relays in the holder Release all the connectors on rear of relay carrier ar...

Page 159: ...nit page 155 Adapting onboard supply control unit page 155 Performing final control diagnosis of onboard supply control unit page 155 General description The onboard supply control unit J519 is fasten...

Page 160: ...cing onboard supply control unit page 155 must always be carried out for reading the codes stored in the control unit The following illustrations show removal on a LHD vehicle Removal and installation...

Page 161: ...e coded online after which the factory mode must be deactivated and the data bus diagnostic interface J533 recoded The programmes will be entered in the test schedule Renew onboard power supply contro...

Page 162: ...o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 Connectors 3 1 Repairing electrical wiring harnesses and plug in connec tions...

Page 163: ...esting and infor mation systems All instructions and notes regarding this chapter are available un der Electrical System General Information Rep gr 97 Vehicle diagnosis testing and information systems...

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Volkswagen up! 2012, Workshop Manual

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Summary of Contents for up! 2012

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