how to read wiring diagrams - justanswer...j 2 20 t121/ 76 sw/ws 0,35 t121/38 e 45 e 227 ws 0,35...

J220

T121/76

sw/ws0,35

T121/38

E45 E227

ws0,35

T121/75

bl/gr0,35

T10e/3 T10e/9

T10e/1

sw/ge0,35

sw/ge0,35

ws0,35

bl0,35

sw/bl0,35

T10s/7

T10s/5

T10s/4

T10s/2

T10s/6

3 2 0 1

T121/57

T10e/2

T10s/3

ro/ge0,35

A20 k

ro/ge0,35

128 129 130 131 132 133 134 135 136 137 138 139 140127

i i

sw/bl0,5

169

gn0,35

ro/li0,35

3 4

T121/27

G70

bl/ge1,5

2

sw0,35

5

T121/29

T121/53

S3/4

17/30

23/87

J1720 18/C

4

22/50

21/31

S2/5

24/TK 19/86

16/85

T121/65

li/ws0,5

T6/2

S3/6

sw0,5

S3/3

20

li/ws0,5

S3/5

ro/sw1,5

S3/2

br/ge0,5

S3/1

196

li/ws0,5

A125

J234T75/72

12

li/ws0,35

3131 a

jHow to ReadWiring Diagrams

Symbols, Layout and Navigation

Self-Study ProgramCourse Number 873003

Volkswagen of America, Inc.3800 Hamlin RoadAuburn Hills, MI 48326Printed in U.S.A.August 2001

Volkswagen of America, Inc.Service TrainingPrinted in U.S.A.Printed 8/01Course Number 873003

©2001 Volkswagen of America, Inc.

All rights reserved. Information containedin this manual is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at anytime without notice. No part of this documentmay be reproduced, stored in a retrievalsystem, or transmitted in any form or by anymeans, electronic, mechanical, photocopying,recording or otherwise, nor may these materials be modified or reposted to other sites without the prior expressed writtenpermission of the publisher.

All requests for permission to copy and redistribute information should be referred to Volkswagen of America, Inc.

Always check Technical Bulletins and theVolkswagen Worldwide Repair InformationSystem for information that may supersedeany information included in this booklet.

i

Table of Contents

Course goals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Wiring Diagram Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Elements of a wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5DIN 72 552 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Introduction to Conductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Wire colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Wire sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Other Conductor descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Connector Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Practical Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Navigation 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Navigation 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Navigation 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Navigation 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Appendix A: Component Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 31Appendix B: Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Appendix C: Component Codes and Wiring . . . . . . . . . . . . . . . . . . . 35Appendix D: DIN Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Appendix E: Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Teletest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Page

ii

Course goals

This course will enable you to:• Follow current from its power

source to the Ground point quicklyand accurately.

• Understand the symbols of common components and circuit designations used in VolkswagenWiring Diagrams.

• Practice Wiring Diagram navigationthrough practical exercises and handson examples.

Course Goals

1

Introduction

As today’s vehicles become increasinglycomplex, so does the job of the technician.Wiring diagram navigation skills are critical todiagnosing and repairing today’s vehicle in atimely and accurate manner.

This Self Study Program is not intended toinstruct the technician how the electrical sys-tem operates in a vehicle. Given an under-standing of electrical operation, this SelfStudy Program will introduce you to the skillsnecessary to read Volkswagen wiring dia-grams.

In this program you will be exposed to allaspects of wiring diagrams, including:

• Commonly used symbols and theirmeanings

• Current tracks, including how tofollow circuits between pagesor diagrams

• Component identification

• DIN standards for terminal designations

• Wiring color codes and gauge (size)

• Terminal identification on bothconnectors and components

This book will provide examples of varioustypes of circuits. The Computer BasedTraining (CBT) CD included at the end of thisself study will provide an opportunity to prac-tice “hands-on” wiring diagram navigation.

Areas of text that give the technician anopportunity to practice the concepts in theCBT will be designated with an icon of a CD(below) at the beginning of that section.

Introduction

Overview

Volkswagen wiring diagrams are a graphicrepresentation of the actual vehicle wiring.They are developed from the engineeringdrawings that are used to produce the wiringharness. A consistent set of symbols areused to represent the actual componentsand conductors.

Volkswagen electrical systems and wiringdiagrams follow the German DIN (DeutscheIndustrie Norm/Deutsches Institut fürNormung) standards. These standards areguidelines for manufacturing in Germany,similar to SAE (Society of AutomotiveEngineers) in the United States.

Layout

The layout of wiring diagrams is common toall Volkswagen vehicles. Called “CurrentTrack” wiring diagrams, they show thepower source at the top of the page and theGround points at the bottom. Situated verti-cally between power and Ground are thecurrent tracks, which contain electrical com-ponents and conductors.

This current track layout simplifies the wiringdiagram. Conductor symbols crossing wherethey do not connect is kept to a minimum.Refer to the example on page 3 for the basiclayout of the wiring diagram.

Central/relay panel

The central/relay panel is indicated in gray atthe top of the wiring diagram page. The cen-tral/relay panel includes common power cir-cuits, such as battery power (30), ignitionswitched power (15), load reduction (75/X),and Ground (31).

Ground Connections

Ground connections are represented as aline at the bottom of the wiring diagrampage, directly above the current track num-bers. All Ground connections, whether theyoccur as a splice in a harness, or the finalGround source, are numbered and identifiedin the wiring diagram.

Conductors and components

Between the central/relay panel and thevehicle ground at the bottom of the diagramare located the component symbols andconductors. Components are marked with acomponent code listed in the legend.Conductors are generally marked with wirecolor and size.

Current tracks

Individual current tracks are identified numer-ically along the base of the wiring diagram.These numbers are used to find the continu-ation of a conductor. Where the system orcircuit layout is complex, this continuationmay be on the same page, or on a differentpage.

For example, the number 191 inside of thesmall box on page 3 indicates that the wireis continued on current track 191. Followingstraight down on the diagram, we see thatthis wire is on current track 5. If we were tonavigate to current track 191, we would seethe same color and size wire with a smallbox containing the number 5.

Legend

Below the current track numbers you’ll find alegend of the components (by componentcode) found in the specific diagram. This willoften detail the location of a given compo-nent or connection.

Wiring Diagram Overview

2

3

Navigation

Navigation in the wiring diagram is based around the use of the current track numbers. Youwill generally start with the affected component and then follow the associated circuit fromthere, tracing Power, Ground, and signals that affect the component’s operation.

Wiring Diagram Overview

Elements of a wiring diagram

In this section, we will look at how varioussymbols are used in a wiring diagram to rep-resent the actual components on the vehicle.

Every circuit needs a minimum of the follow-ing to operate:

• Power supply

• Consumer (load)

• Ground

• Conductors (usually wire)

If any of these are missing, a complete cir-cuit is broken and the consumer will notfunction. The ability to break down a circuitinto its individual parts is the key to beingable to diagnose failures in the circuit.

4

Wiring diagrams incorporate many symbolsused to illustrate a complete circuit. Thesesymbols can include:

• Current track numbers

• Components

• Terminal designations

• Conductors

• Connectors

Together these components make up a com-plete and accurate wiring diagram.

Elements of a Wiring Diagram

5

Symbols

Graphical representations called "symbols"are used to represent components and con-ductors in wiring diagrams. The key to read-ing wiring diagrams is understanding thesymbols.

These symbols are standardized, allowingquick recognition of various components.

DIN Standard 72 552

This standard applies to the terminal desig-nations for circuits. The purpose of the termi-nal designation system is to enable accurateconnection identification from conductors(wires) to various components when diagno-sis and repair is necessary. Examples of DINstandards for terminal designations areshown below:

1 Ignition coil primary4 Ignition coil secondary15 Ignition switched, on and

start30 Battery +31 Ground31b Switched Ground50 Starter control 75/X Load Reduction/Ignition

switched on only

The terminal designations do not identify thewires, but the type of circuit. For this reason,the designations are not placed on the wiresin the diagram, but on the component. Referto Appendix D on page 36 for a more com-plete list of terminal standards. Be awarethat some abbreviations are used, and theymay be abbreviations of German words. Forexample, “GRA” is the abbreviation for“cruise control”, and VL is the abbreviationfor “left front.”


The following list shows the German abbre-viations to the English text for the mostcommon colors. Refer to appendix C forother color code definitions.

bl . . . . . . . . . . . . . . . . . . . . . Bluebr. . . . . . . . . . . . . . . . . . . . . Brownge . . . . . . . . . . . . . . . . . . . . Yellowgn . . . . . . . . . . . . . . . . . . . . Greenro. . . . . . . . . . . . . . . . . . . . . Redsw . . . . . . . . . . . . . . . . . . . . Blackli . . . . . . . . . . . . . . . . . . . . . Violetws . . . . . . . . . . . . . . . . . . . . White

Wire sizes

Wiring diagrams also indicate the wire gaugeused (shown in mm2), designating the crosssectional area of the wire. Because standardsexist for the maximum permissible voltagedrop across a circuit, wire gauge is critical. Ifthe voltage drop across the wire is too high,one or more of the following may occur:

• The circuit may overheat

• The consumer may not operateproperly (due to low voltagecondition)

• Components may be damaged

If a wiring repair needs to be made and met-ric sized wire is not available, the technicianmay need to use American Wire Gauge(AWG) sized wire.Note:• If the exact size wire is not available for a

repair, use the next larger size.• For more information on wiring, refer to

the Wiring Harness Inspection andRepair SSP (course number 871003).

6

Introduction to Conductors

The wiring harness and related componentsmay contain many different types of conduc-tors, including wires, internal connections,threaded connections, welded connections,push-on connectors, multiple point connec-tors and Ground.

The complete list of wiring connections andsymbols is shown in Appendix B.

Wires

Wires are conductors that carry current tocomponents, and are usually indicated by asolid line. A wire shown as a dashed line in awiring diagram indicates that the wire doesnot apply to all vehicles, and is noted in thewiring diagram legend.

Wire colors

Knowing the standards for wiring colorsmakes the job of reading and interpretingthem easier. Some of the common stan-dards include wiring color for specific cir-cuits, as well as the terminal designation.For example:Red . . . . . . . . . . . . . . . . . . . Battery +Green. . . . . . . . . . . . . . . . . . Ignition (1)Brown . . . . . . . . . . . . . . . . . Ground (31)Yellow . . . . . . . . . . . . . . . . . Headlights (58)

Once the technician has an understanding ofthe color guides, the job of isolating systemsbecomes easier.

Wire colors are shown as abbreviations ofthe German word for the color.


7

Other conductor descriptions

Internal conductors exist inside compo-nents, acting as bridges between the wiringharness and the final consumer. In somecomponents these conductors are labeled inthe component. An example would be the30 circuit (Battery +) in the central/relaypanel. In other components the conductor isnot labeled. Internal conductors are shownas thin, black lines.

Physical contact

Some components, such as the starter orgenerator, may receive Ground where theyare bolted to the engine or transmission.This is also shown as a thin black line.

Welded connections are used in wiring har-nesses to join multiple, smaller gauge wiresto a single larger wire which terminates atthe fuse relay panel or chassis Ground.

Sometimes a welded connection is shownwith the thin line not terminating at anotherwire. This symbolizes that this welded con-nection is used in other diagrams for the car.The technician may need to reference otherdiagrams to locate components or Groundsrelated to this connection.

Threaded connectors are commonly usedon the bottom of the fuse relay plate to dis-tribute power and Ground to components.The common connectors include Batterypower, Ground and load reduction (X).


Ground

The vehicle chassis acts as a commonGround conductor throughout the vehicle,and is identified by the line at the bottom ofthe wiring diagram above the current tracknumbers.


8

Some wiring diagrams will show ground des-ignations at the bottom of the wiring dia-gram that are actually welded ground con-nections in the harness (see illustrationSSP 8730/75). In practice, you may need tosearch through the legend to find where awelded ground connection finally attaches tothe vehicle chassis.

Other wiring diagrams will show weldedGround connections in the wiring harness,as shown in illustration SSP 8730/79.

9

Connector pin assignments

Wiring diagrams tell the user at which pinnumbers the wires terminate, simplifyingdiagnosis.

There are 4 main types of terminal designa-tions:

• Push-on/multi-point connections

• Component/multi-point

• Central/relay panel

• Relay

Push-on/multi-pin connectors use the "T"designation, and are identified in the legend.For example, T8a/5 designates an 8-pin con-nector, with the specified wire located in ter-minal 5 of the connector housing. The leg-end will give additional information aboutthis connector. For example: "8-Pin connec-tor, brown, in engine compartment, in wiringduct, left" (see Wiring Diagram example 41beginning on page 61 for specific examples).

Generally, pin assignments are labeled onthe plastic hard-shell connector housingand/or the corresponding component. Onlarger connectors, pin assignments arelabeled at either end of a row. For example,the Engine Control Module (ECM) plug oftenhas 2 or 3 rows of 12 or more terminals.Each row will be marked on each end tofacilitate easier diagnosis.


Component/multi-point pin assignmentsmay or may not use the "T" designation.Some are numbered sequentially. Othersmay use DIN circuit designations, or a com-bination of these methods. See example atright, and find two examples in wiring dia-gram 29 (Appendix E).

Central/relay panel connections enter orexit as either threaded connections, or multi-point connectors. Threaded connectors areidentified in the legend, and may be identi-fied on the component with the DIN circuitdesignation.

Multi-point connectors on the back of thepanel are not identified in the legend. Theywill have a letter and possibly a number toidentify location, followed by the pin number.For example S1/5 would be connector S1,pin 5.


10

2 3 4 5 6 7 8 9 10 11 12 13 14

S177110A

S16440A

S16350A

S16250A

S18030A

S17930A

S17830A

5 4 3 2 1 T3/3 T3/2 T3/1

2.5sw

2,5ro/gr

0,5ro/gr

A41

86S1550b50PX

2,5sw/ro

30 30

131 57 124

2,5ro

1,5ro

1,5ro

2,5ro

D

A32

6,0ro

6,0ro

501

3175

5/31

8/75

7/30

6/75X

J59

S1/5503

0,5sw/ro1,5

sw/ge10,0

sw/ge

191 169

A80

2,5sw/ro

1,5sw/ro

134 138

SSP 8730/55

11

Relay connections list the terminal cavitynumber on the relay socket, followed by thepin identification on the relay. Illustration SSP8730/65 shows that cavity 2 of the harnessconnector is associated with the DIN termi-nal 30 of the relay. Both may be used duringdiagnosis of the circuit.

Note:When diagnosing electrical concerns usingthe VAG 1598 pin-out box, the pin numberson the control module and multi pin connec-tor usually match the pin numbers on thetool.

When using the VAG 1466 pin-out box, thenumbers on the relay or control module andsocket usually do not match those on thetool. These must be noted before beginningdiagnosis.


12

A commonly used symbol is the resistor,used to create a voltage drop in a circuit.Below are three types of resistors:

A standard resistor has a fixed resistance.

A rheostat, or potentiometer, varies itsresistance based on mechanical input. Anexample of this is the Throttle PositionSensor (TPS) on a Motronic equipped car(SSP 8730/57).

A temperature dependent resistor variesits resistance based on temperature. Thistype of resistor is used as the EngineCoolant Temperature (ECT) sensor on anengine management system, or theInterior Temperature sensor on modelswith climate control (SSP 8730/56).

When a resistor is used as a sensor, it gen-erally carries a component designator “G.”

Note:Any time the temperature symbol (left) isattached to another symbol, it signifies thatthe operation of that component will varywith temperature.


Components

Components in wiring diagrams are given an alphanumeric designation for identification. Thefirst portion of the code separates the component into basic groups. An F for example, des-ignates a switch, while a Z would be used for a heating element. A complete list of thesedesignations are shown in Appendix C on page 43. The second part (numeric) designateswhich component is covered inside of these main groups.

Example: Evaporative Emissions (EVAP) Canister Purge Regulator Valve N80. N designates asolenoid valve, 80 clarifies which solenoid is being dealt with.

SSP 8730/21

Resistor

VariableResistor

(Rheostat)

TemperatureDependant

Resistor

13


The switch is another component used tocontrol current flow. The basic symbols foran open and closed switch are shown inillustration SSP 8730/22. An example of thissimple two-position switch would be a glovecompartment light switch. A simple switchuses the component designation “F.”

There are many types of designs, includingmechanically actuated, pressure actuated,temperature actuated and momentary.Examples include:

• Oil pressure switch (pressure actuated)

• Cooling fan thermo-switch (temperatureactuated)

• Brake Switch -F- (mechanically operated)

More complex circuits may require a switchwith multiple sets of contacts. An exampleof this would be the cruise control switch.

As you can see in illustration SSP 8730/25,there are multiple sets of contacts withinthe assembly. Depending on the position ofthe switch, various sets of contacts are openor closed. Careful study of the symbolsallows the technician to follow the circuitthrough the switch under any condition.

A complex switch uses the component des-ignation “E”.

Normally openswitch (NO)

Normally closedswitch (NC)

SSP 8730/22

Pressureoperatedswitch

Thermallyoperatedswitch

Mechanicallyoperatedswitch

3 2 0 1

E45 E227SSP 8730/25

Note:All switches and relays are shown in a non-operated state.

Fuses are used to prevent excessive currentfrom damaging other components in a cir-cuit. There are various types, including stan-dard fuses, thermal fuses (circuit breakers),and strip fuses. Fuses use the componentdesignation “S”, their symbols are shownbelow:

The example below shows strip fuses andstandard fuses as seen in a current modelvehicle.

14


Solenoids are used to actuate many differ-ent components, including fuel injectors andrelays.

A solenoid is a coil of wire wrapped aroundan iron core. When current is passed throughthe wire, a magnetic field is induced. Thispulls a set of contacts in the relay closed,either opening or closing the circuit.

Complex Symbols

Often the internal schematic of the compo-nent is shown to allow the technician to fol-low current flow through the component.

These internal symbols are a combination ofseveral basic symbols. This allows the techni-cian to take a more complex symbol andbreak it down into its smaller components.Even the most complex components arenothing more than a combination of smallerbasic symbols.

More complex components may containcomplex control circuitry. This will be indicat-ed with the symbol of a transistor in thecomponent symbol (see control module).

SSP 8730/23

SolenoidArrow indicates

direction of forceSSP 8730/24

15

A relay is an example of a combination ofsymbols in a single component.

Relays require a signal from an outsidesource to activate. Volkswagen vehicles usecommon Bosch®-type 4-pin relays on manycircuits, to remove electrical load from theswitch. Relays share the component desig-nator “J” with control units.

The basic 4-pin relay (below) contains twoseparate components: a switch and asolenoid.

The coil in the solenoid is energized with lowcurrent, creating a magnetic pull that closesor opens the switch.


RelaySSP 8730/26

87

30

85

86

SSP 8730/49

The 4 pins of a standard relay are generally(but not always) numbered as follows:

30 Receives Battery power (switched toconsumer)

87 High load to the electrical consumer

86 Ignition switch, Battery+, loadreduction (X)

85 Receives a switched ground toactivate the solenoid winding in therelay

Note:A production number may appear on top ofthe relay (see illustration SSP 8730/61). Thisnumber may be referred to in the wiringdiagram for diagnostic purposes. See page45 for examples.

However, do not rely solely on this informa-tion when diagnosing a circuit, as this num-ber may change in production. Always referto the parts information system for the cur-rent replacement part numbers.

Note:All switches and relays are shown in a non-operated state.

The last of the more common symbols wewill look at are the Electric motor and theElectronic Control Module.

Electric motors are used throughout thevehicle for numerous applications, includingthe Windshield Wiper Motor and the FuelPump.

At the top and bottom of the motor symbolthere are dark squares, representing thebrushes in the electric motor.

If there are only two brushes, it is a singlespeed motor. The rear window wiper motorshown in illustration SSP 8730/62 is anexample of a single speed motor.

If there are three brushes, the motor hastwo speeds. In the case of the two speedmotor, the upper set of brushes are the lowand high speed brushes.

The windshield wiper motor shown in illus-tration SSP 8730/66 is an example of a twospeed motor.

16


Single speedmotor

SSP 8730/28

Two speedmotor

17

Control Modules can make the task ofreading and interpreting wiring diagramsmore difficult because multiple signals enterand/or exit, but the internal schematic is notalways shown.

The Transmission Control Module (TCM)J217 seen in illustration SSP 8730/63 is anexample of a common control module.

Some control modules may be integratedwith other components.

Take, for example, the window motor withcontrol module. Both the motor and the con-trol module are combined to make a singlecomponent (SSP 8730/74).

The symbol below represents the combinedcomponents.


Control ModuleSSP 8730/44

J296

1 2 3 4 8

765 V15

11. Component symbolsA graphical representation of a component type. See Appendix A, page 35.

12. Wire cross section size (in mm2) andwire colorsAbbreviations are explained in the colorchart beside the wiring diagram.

13. Component symbol with opendrawing sideIndicated component is continued onanother wiring diagram. The number ofthe corresponding wiring diagram can befound in the table of contents.

14. Internal connections (thin lines)These connections are not wires. Internalconnections are current carrying and arelisted to allow tracing of current flowinside components and wiring harness.

a. Internal Harness Splice (Welded Connection)b. Physical Contact (Mounted to engine)

15. Reference of continuation of wire tocomponent (inset)For example: Control module for anti-theft immobilizer J362 on 6-pin connectorterminal 2.

16. Central Relay panel connectorsShows wiring of multi-point or singleconnectors on central relay panel.For example: S3/3 equals Multi-point connector S3, terminal 3.

17. Reference of internal connectioncontinuationLetters indicate where connectioncontinues on previous and/or nextpage.

18. Central Relay Panel

19. Ground Pathex.: from welded harness connection 135 to welded harness connection 81 to weldedharness connection 42.

18

Layout

1. Relay location numberIndicates location on relay panel. See page 1 ofindividual wiring diagram for details.

2. ArrowIndicates wiring circuit is continued on the previous and/or next page.

3. Connector designation - relay/controlmodule on relay panelShows relay panel terminals withcorresponding relay terminal.For example: 17/30 equals terminal 30 of relayconnects to terminal 17 of central relay panel.

4. Threaded pin on relay panelWhite circle shows a threaded removableconnection.

5. Fuse designationFor example: S228 equals Fuse 28, 15 amps,in fuse holder.

6. Reference of wire continuation(current track number)Number in frame indicates current track where wire is continued (see page 3 for example).

7. Wire connection designation in wiringharnessLocation of wire connections areindicated in the legend.

8a. Terminal designation on a multipoint connector8b. Terminal designation on a component

Designation which appears on the actualcomponent and/or terminal number of amulti-point connector.

9. Ground connection designation inwire harnessLocations of ground connections areindicated in legend.

10. Component designationUse legend at bottom of page to identify the component code.


19


1

1

2

34

5 6

7

8a

8b

9

10

10

6

11

12

13

14a

15 (inset)

16

17 18

19ColorCodes

Editionnumber

Page Contents (from WiringDiagram Table of Contents)

Wiring Diagram Number and Page

Legend

14b

5

20

Working with wiring diagrams

When working to diagnose electrical con-cerns on vehicles, it is important that youhave the correct wiring diagram. Not only arethere different models and year, wiring har-nesses will often change in the middle of amodel year. There may be differencesbetween models of the same type and year,but built in different factories.

Within models, there are also different levelsof equipment. For example, the wiring forthe fresh air blower of a vehicle withClimatronic will be different from one with-out Climatronic. Different engines, transmis-sions, even trim levels will mean differences.Always check that the wiring diagram is rightfor the vehicle in question.

It may be necessary to check more than onewiring diagram for the model you are servic-ing. A vehicle's wiring harness is often splitinto several different wiring diagrams.Engine, transmission and power accessorywiring diagrams will only show wiring forthose specific systems.

Working With Wiring Diagrams

When choosing a wiring diagram for diagno-sis of an electrical concern, you should firstconfirm the vehicle model, model year, andproduction date, where applicable. Next,identify if the affected system is part ofvehicle “standard equipment” or “additionalequipment”. Locate the appropriate wiringdiagram by using the index.

A standard equipment diagram will show thevehicle with its base level wiring. Base levelwiring is defined as the most basic possiblerolling chassis, and this may be differentthan what is normally considered “standardequipment”.

For example, all 2001 m.y. Golfs and Jettassold in the US and Canada come withDaytime Running Lamps as “standard equip-ment”. However, the Daytime RunningLamps are shown in a separate wiring dia-gram.

Wiring diagrams are automatically shippedto your dealer. Periodic updates can includeboth new wiring diagrams and updatedpages for existing diagrams.

Wiring diagrams also exist as part of theVolkswagen Electronic Service InformationSystem (VESIS). The advantages of electron-ic wiring diagrams include easy updating,pages that don't get dirty or lost, and searchcapabilities that can make searching for acomponent much easier.

21

Practical Examples

Practical Examples

The preceding sections of this book gaveexamples of the symbols and layout of ourcurrent track wiring diagrams. In the follow-ing section we will examine current flowusing navigation exercises. In these exam-ples, we will look at:

• how battery power is provided to acomponent

• how consumers are actuated usingrelays

• how to split up a circuit to simplifydiagnosis

• the importance of looking in multiplewiring diagrams

Appendix E, starting on page 39, containsthe complete wiring diagrams number 29and 41. Within the navigation exercises, mag-nified views of specific sections of theseWiring Diagrams may be shown. Note that,for clarification purposes, certain compo-nents found in the Wiring Diagrams may notbe shown in these magnifications.

22

Navigation 1

In this example we will look at the circuit forthe load reduction relay. The following pagecontains the complete diagram for thisexample.

The Load Reduction circuit supplies power toconsumers such as the windshield wipermotor and fresh air blower motor when theignition switch is in the "ON" position. Withthe ignition switch in the “START” position,the circuit is de-energized. This lowers theload on the electrical system when startingthe vehicle.

Locate the Load Reduction Relay J59 on thewiring diagram on page 23. The relay con-sists of two separate circuits: the solenoidcircuit, and the switch circuit. In order tosupply power to the consumers in the loadreduction circuit, the solenoid in the relaymust be energized. To do this, terminal 8/75must be supplied with power. The groundside of the solenoid receives an internalground from the central relay panel at pin5/31.

Starting at the Positive (+) terminal of theBattery (A), follow battery power (30) to thefuse box through a 16.0 ro wire.

Power then passes through S176, a 110Afuse, and exits the fuse box at terminal 4.From terminal 4, follow the 16.0 ro wire tothreaded connection 500 on the central relaypanel.

Power passes through the central relay paneland exits at threaded connection 501. Fromthe relay plate, follow the 6.0 ro wire towelded connection A32 in the instrumentpanel wiring harness.

Note that the wire that supplies the powerto the welded connection is larger than otherwires that leave the connection. This fact canbe useful in diagnosis. When tracing out aweld with many wire connections, thelargest wire will usually be the one that goesdirectly to power or ground.

From the welded connection, a 2.5 ro wiregoes to terminal 30 of the Ignition/Starterswitch D. When the Ignition switch is movedto the "ON" position, power continuesthrough the switch to the X contact. Powerexits the Ignition switch through the 2.5sw/ro wire on current track 9.

Follow the wire to welded connection A80.Another similar wire leaves this welded con-nection on current track 8, which connectsto the central relay panel at terminal S1/5.Power flows from this terminal through theinternal connection to terminal 8/75 of therelay.

Because relay terminal 5/31 is alreadygrounded at the central relay panel, the sole-noid is energized. This closes the switch andsupplies power from terminal 500 (30), toterminal 503 (75/X) on the relay panel. Fromterminal 503, power can flow to the con-sumers on the circuit as needed.

Navigation 1

23

Navigation 1

Golf/JettaWiring diagramNo. 1/2

Battery, ignition/starter switch Edition 08/99USA.5102.04.21

BatteryStarterIgnition/Starter SwitchLoad Reduction RelayFuse -1- (30) in fuse bracket/batteryFuse -2- (30) in fuse bracket/batteryFuse -3- (30) in fuse bracket/batteryFuse -4- (30) in fuse bracket/batteryFuse -5- (30) in fuse bracket/batteryFuse -6- (30) in fuse bracket/batteryFuse -7- (30) in fuse bracket/batteryFuse -8- (30) in fuse bracket/battery3-Pin Connector

ABDJ59S163S163S164S176S177S178S179S180T3

-------------

Ground strap, battery to body-1

500

2

501

503

A32

A41

A80

-

-

-

-

-

-

-

-

Ground strap, transmission to body

Threaded connection -1- (30) on the relay plate

Threaded connection -2- (30) on the relay plate

Threaded connection -2- (75x) on the relay plate

Plus connection (30), in instrument panel wiringharnessPlus connection (50), in instrument panel wiringharness (gasoline engines only)Connector -1- (X) in instrument panel wiringharness

Manual transmission only

Automatic transmission only

ws = whitesw = blackro = redbr = browngn = greenbl = bluegr = greyli = lilacge = yellow

1 2 3 4 5 6 7 8 9 10 11 12 13 14

S177110A

S176110A

S16440A

S16350A

S16250A

S18030A

S17930A

S17830A

5 4 3 2 1 T3/3 T3/2 T3/1

a

b

1,0br/ro

2.5sw

2,5ro/gr

0,5ro/gr

119A41

86S1550b50PX

2,5sw/ro

30 30

131 57 124

2,5ro

1,5ro

1,5ro

2,5ro

D

A32

6,0ro

6,0ro

501

3175

5/31

8/75

7/30

6/75X

J59

S1/5503500

0,5sw/ro1,5

sw/ge10,0

sw/ge16,0ro

191 169

A80

2,5sw/ro

1,5sw/ro

134 138

2

35,0sw

35,0sw

16,0ro

-

+

35,0ro

B/30

21

97-26047

24

Navigation 2

This example will follow the flow of powerfrom its source, through a switch, and to aconsumer. This example will build on ourunderstanding of the Load Reduction circuitas seen in Navigation example 1.

The example we will use is a typical horn cir-cuit. The horn circuit on all Volkswagen vehi-cles is similar in design. The main compo-nents of the system are as follows.

• Mechanically operated switch (hornbutton)

• Relay

• Horns (high and low tone)

• Connecting wires

In order to follow these types of circuits, it isbest to split the circuit into two sections.We will first look at the solenoid side of therelay circuit, then the switch side.

Note:Refer to wiring diagram 29 in appendix E forthis example.

From the table of contents for wiring dia-gram 29 (page 39), we see that the horn cir-cuit is shown on page 29/15.

Locate the horn relay (J4) on page 29/15.Starting at the solenoid side of the symbol,follow the internal connection from terminal4/75 across the central relay panel until it ter-minates at an internal connection that runsbetween terminal S1/5 on the back of thecentral relay panel, and terminal 8/75 of relayJ59 on wiring diagram page 29/2. Lookingat the legend, we see that J59 is the Loadreduction relay.

Looking at the wiring for J59 we see thatthe internal connection we are concernedwith here is the power that activates theload reduction relay. Follow the 0.5 sw/rowire down current track 8 to plus connectionA80, across to current track 9 and up to ter-minal X of component D.

We can see that power will flow from thebattery, through fuse S176, and through theignition switch to the horn relay when theignition switch is in the on position. Now,back on page 29/15, let's take a look at theground side of the Horn relay solenoid.

From J4, follow the ground side of the circuitfrom terminal 1/71 of the relay to S1/6. A0.35 br/bl wire runs from the central relaypanel to T5b/3. The legend identifies T5b as a5 pin connector on the airbag spiral spring(F138).

From the spiral spring, the circuit continuesthrough another 5 pin connector, T5j, throughmanually operated push button switch H (thehorn contact), and then back though the spi-ral spring to T5b/2. From this terminal a 0.35br wire runs to welded ground connection135, in the instrument panel wiring harness.

Looking at 135, we see no less than 9 wiresin the weld! In practice, you may need totrace out every wire in the weld to find aproblem. Let's use the trick we discussed inthe last example to narrow down the field.Looking at the left side of connection 135,we see a 4.0 br wire connecting to anotherinternal connection, marked with the contin-uation "o."

Navigation 2

25

Navigation 2

Follow "o" in both directions. It is identifiedas welded ground connection 81, in theinstrument wiring harness. It is connected toground at two points; ground 49 at currenttrack 182, and ground 42 at current track201. We now have the complete circuit forthe solenoid side of the relay.

Let's look at the horns and the switch circuitof the relay. Follow the internal connection"m" from terminal 3/30 at the relay to thefuse box at current track 153. Continue tofollow the source of the power through thefuse and the current track continuation backto page two of the wiring diagram.

As seen in Navigation example 1, the powercomes from the battery, through fuse S176,to threaded connection 500. From there itruns though the central relay panel tothreaded connection 501, to the fuse box atfuse 40 (S240), and to the relay though thecentral relay panel. When the relay is acti-vated by pushing the horn contact, powerwill flow to the horns through S2/2, thoughwelded connection A90, to terminal 2 oneach horn.

Tracing the ground side of the horns, we seethat they jump to current tracks 74 and 75from tracks 183 and 185, respectively. Goingto current tracks 74 and 75, follow the brownwires to internal connection marked "d". Wefollow that along to find that it is weldedconnection 179, which goes to Groundthough a 4.0 br wire at ground connection12, in engine compartment left, shown oncurrent track 61. We now have the completecircuit for the horns.

26

Navigation 3

In this exercise, we will again examine theactivation of an electrical consumer througha simple 4-pin relay. Let's look at the naviga-tion from the point of view of diagnosing aninoperative motor. In this circuit we will lookat the Secondary Air Injection (AIR) pumpmotor V101.

To diagnose this circuit, we need to under-stand that the secondary air system is acti-vated by the Motronic ECM at certain timeswhen the engine is running, and that we cantrigger this function using the VAS 5051 scantool. Assume that we have already attempt-ed this, and the pump does not run. Alsoassume that the only DTC in the systemsmemory is the Secondary Air DTC.

Note:Refer to the illustrations on pages 26-28 andwiring diagram 41 in appendix E for thisexample.

From the table of contents for wiring dia-gram 41 (page 40), we see that theSecondary Air circuit is shown on page41/12.

Locate the Secondary Air Injection (AIR)pump relay J299 on wiring diagram page41/12. We will once again split the circuitinto two parts to simplify diagnosis. Let'sstart with the switch side of the relay.

From motor V101, follow the 4.0 br wiredown to the current track continuation (illus-tration SSP8730/11), and over to page 41/5.The wire goes directly to Ground 609 in theright side of the plenum chamber. Now let'strace the power side.

Navigation 3

2/87

1/30

3/85

299

V101

2

gr/br1,0

4/86

1

M

ws/ro4,0

bl/ge1,5

ro6,0

6

J

br4,0

148 149 150 151 152

52

SSP 8730/11

i5 6 7 8

4

S176110A

5

S177150A

2

S16350A

A/+

sw25,0

1

S16250A

ro6,0

149

SSP 8730/12

609

149

br4,0

51 52 53

SSP 8730/17

27

Returning to current track 149, we see thatthe 4.0 ws/ro wire runs to the switch portionof the relay (illustration SSP8730/11).Following the 6.0 ro wire from where itleaves terminal 1/30 on the relay, through itscurrent track continuation, we see that themotor receives direct battery power (30)from fuse S162. Checking the fuse on thevehicle shows it to be good.

Locate relay J299, and pull it from its socket.Using a wire from the VAS 1978 wiring repairkit of the proper size, and with the propersize terminals, we can jump the relay socketfrom terminal 1/30 to 2/87. The Secondary AirInjection (AIR) pump motor V101 runs, verify-ing that this section of the circuit is function-ing correctly.

Let's trace out the power side of the sole-noid in the relay. Terminal 85 on a standard4-pin relay is usually the power side.Following the 1.5 bl/ge wire down, we seethat it leads to welded connection continua-tion "i".

In both directions along "i", we see that thisis welded connection E30 in the enginewiring harness. It supplies power to many ofthe actuators in the engine managementsystem. Since there are no other faults inthe Engine Management System, we canassume that fuse 43 (S243) on current track156 is good. To test this circuit correctly, let'strace that power back to its source.

Following the circuit from Fuse S243 up tothe central relay panel and over internal con-nection "j", we see that this power comesfrom the switch side of J17, the fuel pumprelay. This is important for testing. We knowthat we will only have power at terminal 3/85of the Secondary Air Injection (AIR) pumprelay J299 when the fuel pump relay is ener-gized.

Navigation 3

bl4,0

l

m

10A

34a

34

bl4,0

A100

S234

A99

ge/sw1,0

E30

10A

43a

43

bl/ge2,5

S243

bl4,0

i

T6/5

99

bl4,0

ge/sw1,0

ge/sw1,0

bl/ge2,5

ge/sw0,5

T14a/6

60

T6/6

156 157 158 159155

j

bl/ge1,0

A151

z

SSP 8730/13

504

17/30

23/87

J17

S2/5

31

j

SSP 8730/14

28

2/87

1/30

3/85

299

V101

2

gr/br1,0

4/86

1

ws/ro4,0

bl/ge1,5

ro6,0

6

J

br4,0

149 150 151 152 153

gr/br0,35

T121/66

52

SSP 8730/16

J220

Go to the Secondary Air pump relay J299 onpage 41/12 (or see below). Follow the 1.0gr/br wire from terminal 4/86 to terminalT121/66 on the Motronic ECM J220. Notethat somewhere in the harness it appearsthat the wire enters an unidentified connec-tion, and changes size. This wire carries theground signal that energizes the relay.

Now let's test the solenoid side of the cir-cuit. Connect the appropriate test equip-ment, such as an LED test light, multimeter,or the Digital Storage Oscilloscope of theVAS 5051, between terminals 4/86 and 3/85of the relay socket. We then activate the cir-cuit (using the VAS 5051) and see that theproper signal is going to the relay socket.

Since the circuit appears to be complete, thenext step would be to replace the relay andretest. Doing this, we find that the circuitoperates correctly. We can now check, and ifnecessary, erase any DTCs, quality check thevehicle, and return it to the customer.

Navigation 3

29

Looking at welded connection B163 shows itto be open ended. This often indicates thatthe weld is continued on another wiring dia-gram. Since we located the VSS in the I.8Tengine wiring diagram, one place to lookwould be the Standard Equipment wiringdiagram for this vehicle, number 29.

Looking through the legend at the bottom ofeach page in wiring diagram 29, we findweld connection B163 on page 29/3.

Following the current track continuation fromB163 to current track 122, we find that the1.0 sw/gn wire runs to the backup lightswitch. In the engine compartment, we findthat this wire has been pinched in theengine compartment wiring harness near thestarter. We repair the wire using the VAS1978 wiring repair kit, replace the fuse.Check, and if necessary, erase any DTCs,quality check the vehicle, and return it to thecustomer.

One thing to note: in vehicles equipped withan automatic transmission, the circuit forfuse S7 would be different. We would needto look in the wiring diagram for that systemas well.

Navigation 4

Often, when we are diagnosing an electricalproblem on a vehicle, we will need to look atmore than one wiring diagram. In this finalexample, we will look at a simple problemthat shows the importance of considering allof the applicable wiring diagrams for thevehicle that we are diagnosing.

Let's consider a customer concern of aninoperative speedometer. The vehicle is a2000 Jetta GLS, equipped with a 1.8T engineand manual transmission.

A road test verifies that neither thespeedometer nor the odometer is operating.There is also a DTC stored in the engineECM memory, showing no signal from thevehicle speed sensor (VSS).

Note:Refer to wiring diagrams 29 and 41 in appen-dix E for this example.

From the table of contents for wiring dia-gram 41 (page 40), we see that the vehiclespeed sensor circuit is shown on page41/14.

Looking at wiring diagram page 41/14, welocate the VSS (G22), and trace the powerback to fuse 7 (S7). We find that the fuse isblown. After locating the 14 pin connector inthe engine compartment wiring duct (T14a),and some testing with a multimeter, we findthere is a short to ground between terminal7a on the fuse box, and terminal T14a/2.

Navigation 4

Notes

30

31

Appendix A: Component Symbols

Starter

Battery

Generator

Ignition coil

Distributor(electrical)

Spark plugconnectorand plug

Glow plugheater element

Manuallyoperatedswitch

Thermallyoperatedswitch

Push-button switch(manually operated)

Mechanicallyoperatedswitch

Pressureoperatedswitch

Multiple switch(manually operated)

Heater element(temperature dependent) SSP 8730/02

32

Diode

Zener diode

Light bulb

Light bulb(dual filament)

LED

Diode(light sensitive)

Interior light

Instrument(gauge)

Rear window defoggerheat element

Cigarettelighter

Solenoid valve

Magnetic clutch

Wire connectionin wiring harness

Resistance wire

Shield wire

SSP 8730/03


33


Wiper motor(2-speed)

Crankshaftposition sensor

Analog clock

Digital clock

Multifunctionindicator

Speed sensor

Horn

Control motor,headlight range

adjustment

Camshaftposition sensor

Airbag spiralspring

Speaker

Antenna withelectronic antenna

amplifier

Radio

Heated oxygensensor

SSP 8730/04

34

Appendix B: Wiring Connections

Wiringjunction

Internal connectionin a component

Disconnectedwire terminal

Slip contact

Multipoint connectoror component

Push-onconnector

Wiresconnected

Connectedwire terminal

Wires connected(detachable junction)

Wires notconnected SSP 8730/30

35

Appendix C: Component Codes and Wiring

Color Codes

German Abbreviation to English

bl . . . . . . . . . . . . . . . . . . . . . Bluebr. . . . . . . . . . . . . . . . . . . . . Brownge . . . . . . . . . . . . . . . . . . . . Yellowgn . . . . . . . . . . . . . . . . . . . . Greenro. . . . . . . . . . . . . . . . . . . . . Redsw . . . . . . . . . . . . . . . . . . . . Blackli . . . . . . . . . . . . . . . . . . . . . Violetws . . . . . . . . . . . . . . . . . . . . White

Occasionally in a complex circuit, other col-ors may be used. These are listed below.

el . . . . . . . . . . . . . . . . . . . . . Creamnf. . . . . . . . . . . . . . . . . . . . . Neutralog . . . . . . . . . . . . . . . . . . . . Orangers . . . . . . . . . . . . . . . . . . . . . Pinkhbl . . . . . . . . . . . . . . . . . . . . Light Bluehgn . . . . . . . . . . . . . . . . . . . Light Greenrbr . . . . . . . . . . . . . . . . . . . . Maroonx . . . . . . . . . . . . . . . . . . . . . Braided cabley . . . . . . . . . . . . . . . . . . . . . High tensionz . . . . . . . . . . . . . . . . . . . . . Non-cable

American Wire Gauge (AWG) Conversionto Metric

The conversion from AWG to Metric (mm2)is shown below.

AWG . . . . . . . . . . . . . . . . . . . . mm2

22 . . . . . . . . . . . . . . . . . . . . . . 0.3520 . . . . . . . . . . . . . . . . . . . . . . 0.5018 . . . . . . . . . . . . . . . . . . . . . . 0.7516 . . . . . . . . . . . . . . . . . . . . . . 1.0014 . . . . . . . . . . . . . . . . . . . . . . 1.5012 . . . . . . . . . . . . . . . . . . . . . . 2.5010 . . . . . . . . . . . . . . . . . . . . . . 4.008 . . . . . . . . . . . . . . . . . . . . . . . 6.004 . . . . . . . . . . . . . . . . . . . . . . . 16.02 . . . . . . . . . . . . . . . . . . . . . . . 25.02 . . . . . . . . . . . . . . . . . . . . . . . 35.0

Component Code Prefixes

A BatteryB StarterC Alternator/GeneratorD Ignition/Starter switchE Switches - these are usually more

complex switches: A/C control head,sunroof regulator

F Switches - door, hood, brake, clutch,trunk, multifunction, etc.

G Gauges and sensorsH HornJ Control modules, Relays, Electronic

RelaysK Indicator/Warning lightsL LightsM LightsN Solenoids/Inductors/Ignition - Fuel

injectors, Purge, Ignition coil, Ignitionmodule, etc.

P Spark plug connectorQ Spark PlugsR Radio, CD, Telephone, NavigationS Fuse, circuit breaker, protection deviceT Wire connectorV Motor - Window motors, vacuum

pumps, etc.W Lights - Interior, TrunkZ Heating elements - O2 sensor heater,

heated seats, heated mirrors, etc.

36

DIN standards for terminal designations

The following are examples of the commonVolkswagen DIN list for terminal designa-tions: 1 Ignition coil, ignition distributor - Low

voltage1a To contact breaker I (Ignition distribu-

tor with two separate circuits)1b To contact breaker II (Ignition distribu-

tor with two separate circuits)4 Ignition coil, ignition distributor - high

voltage4a From ignition coil I (Ignition distributor

with two separate circuits)4b From ignition coil II (Ignition distributor

with two separate circuits)15 Switched (+) downstream of battery

(output of ignition/driving switch)15a Output at ballast resistor to ignition

coil and starter17 Glow plug and starter switch - Start19 Glow plug and starter switch - Preheat30 Input from battery (+) term., direct

12/24 V series-parallel battery switch30a Input from (+) terminal of battery II31 Battery negative terminal, or ground,

direct31b Return line to battery negative termi-

nal, or ground via switch or relay(switched negative)

31a Return line to battery II, negative(12/24 V series-parallel battery switch)

31c Return line to battery I, negative(12/24 V series-parallel battery switch)

Electric motors32 Return line33 Main terminal connection33a Self-parking switch-off33b Shunt field33f For second lower-speed range33g For third lower-speed range33h For fourth lower-speed range33L Counterclockwise rotation33R Clockwise rotation

Starters45 Separate starter relay, output; starter,

input (main current)Two-starter parallel operation - Startingrelay for engagement current

45a Output, starter I, Input, starters I and II45b Output, starter II48 Terminal on starter & on start-repeating

relay for monitoring starting

Turn-signal flashers (pulse generators)49 Input49a Output49b Output, second circuit49c Output, third circuit

Appendix D: DIN Standards

37


Starter control50 Starter control (direct)50a Series-parallel battery switch - Output

for starter control50b with parallel operation of two starters

with sequential controlStarting relay for sequential control ofthe engagement current during paralleloperation of two starters

50c Input at starting relay for starter I50d Input at starting relay for starter II50e Start-locking relay Input 50f Start-locking relay Output50g Start-repeating relay Input50h Start-repeating relay Output

Wiper motors53 Wiper motor, input (+)53a Wiper (+), self-parking switch-off53b Wiper (shunt winding)53c Electric windshield-washer pump53e Wiper (brake winding)53I Wiper motor with permanent magnet

and third brush (for higher speed)

Lighting55 Fog lamp56 Headlamp56a High beam, high-beam indicator lamp56b Low beam56d Headlamp-flasher contact57a Parking lamp57L Parking lamp, left57R Parking lamp, right58 Side-marker, tail, license plate, and

instrument panel lamps58b Dimmer58d Dimmer58L License-plate lamp, left58R License-plate lamp, right

Alternators and voltage regulators61 Alternator charge-indicator lampB+ Battery positiveB- Battery negativeD+ Dynamo positiveD- Dynamo negativeDF Dynamo fieldDF1 Dynamo field 1DF2 Dynamo field 2U,V,W Alternator terminals75 Radio, cigarette lighter76 Speakers

Switches

Break contact (NC) and changeoverswitches81 Input81a Output 1, NC side81b Output 2, NC side

Make contact (NO) switches82 Input82a Output 182b Output 282z Input 182y Input 2

Multiple-position switches83 Input83a Output, position 183b Output, position 283L Output, left-hand position83R Output, right-hand position

38


Relays/Current relays84 Input, actuator and relay contact84a Output, actuator84a Output, relay contact

Switching relays85 Output, actuator (end of winding to

ground or negative)86 Input, actuator (start of winding)86a Start of winding or 1st winding86b Winding tap or 2nd winding

Relay contact for break (NC) andchangeover contacts87 Input87a Output 1 (NC side)87b Output 287c Output 387z Input 187y Input 287x Input 3

Relay contact for make (NO) contact andchangeover contacts88 Input88a Output 188b Output 288c Output 388z Input 188y Input 288x Input 3

Directional signals (turn signal flashers)C Indicator lamp 1C2 Indicator lamp 2C0 Main terminal connection for separate

indicator circuits actuated by the turnsignal switch

C3 Indicator lamp 3 (e.g., when towingtwo trailers)

L Turn-signal lamps, leftR Turn-signal lamps, right

39

Appendix E: Wiring Diagrams

Relay locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29/1Battery, ignition/starter switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29/2Instrument cluster, clutch pedal position (CPP) switch,starting interlock relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29/3Instrument cluster, tachometer, speedometer, odometer, display antitheft immobilizer, warning light for anti-theft immobilizer sensor . . .29/4Instrument cluster, generator (GEN) warning light, digital clock,low fuel level warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29/5Instrument cluster, left front brake pad wear sensor, brake pad wear indicator light, headlight high beam indicator light . . . . . . . . . .9/6Instrument cluster, parking brake warning light switch,brake fluid level warning switch, low windshield washer fluid level indication,left and right turn signal indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29/7Turn signal switch, headlight dimmer/flasher switch,left front turn signal light, light for side marker front left, left headlight . . . . . . .29/8Emergency flasher switch, turn signal relay, right front turn signal light,light for side marker front right, right headlight . . . . . . . . . . . . . . . . . . . . . . . . .29/9Back-up light switch, left rear turn signal light, left back-up light,left brake/tail light, high-mount brake light (Golf only) . . . . . . . . . . . . . . . . . . . .29/10Brake light switch, right rear turn signal light, right back-up light,right brake/tail light, high mount brake light (Jetta only) . . . . . . . . . . . . . . . . . . .29/11Data Link Connector (DLC) radio connection, cigarette lighter . . . . . . . . . . . . . .29/12Light switch, rear fog light switch, instrument panel vent illumination . . . . . . . .29/13License plate light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29/14Dual tone horn, fuel tank door remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29/15Instrument panel light dimmer switch, glove compartment light,rear window, defogger switch, heated rear window . . . . . . . . . . . . . . . . . . . . .29/16Fresh air blower, fresh air/recirculating flap switch, fresh air blower . . . . . . . . . .29/17Motor for rear windshield wiper, windshieldand rear window washer pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29/18Windshield wiper/washer switch, windshield wiper/intermittent regulator,windshield wiper motor, wiper/washer intermittent relay . . . . . . . . . . . . . . . . .29/19

Golf/Jetta - Standard Equipment, from May 1999

No./Page

40

Appendix E: Wiring Diagrams

Generator (GEN), starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41/2Motronic engine control module (ECM) power supply relay . . . . . . . . . . . . . . . .41/3Motronic engine control module (ECM) ignition system . . . . . . . . . . . . . . . . . .41/4Motronic engine control module (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41/5Motronic engine control module (ECM), (ECT) sensor, charge air pressure sensor, camshaft position (CMP) sensor 2, wastegate bypass regulator valve, recirculating valve for turbocharger . . . . . . . .41/6Motronic engine control module (ECM), angle sensor for throttle drive (power accelerator actuation), intake air temperature (IAT) sensor, knock sensor (KS) 1,leak detection pump (LDP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41/7Motronic engine control module (ECM), pressure switch/power steering,engine speed (RPM) sensor, knock sensor (KS) 2 . . . . . . . . . . . . . . . . . . . . . . .41/8Motronic engine control module (ECM),heated oxygen sensor (HO2S), injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41/9Motronic engine control module (ECM), throttle position (TP) sensor,oxygen sensor (O2S) behind three way catalytic converter (TWC),evaporative emission (EVAP) canister purge . . . . . . . . . . . . . . . . . . . . . . . . . . .41/10Motronic engine control module (ECM), fuel pump (FP) relay, cruise control switch, mass air flow (MAF) sensor . . . . . . . . . . . . . . . . . . . . . .41/11Motronic engine control module (ECM), secondary air injection (AIR) pump system,brake light switch, clutch vacuum vent valve switch, brake vacuum vent valve switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41/12Fuel pump (FP), fuel level sensor, engine coolant level (ECL) sensor . . . . . . . . .41/13Instrument cluster, oil pressure switch, speedometer vehicle speed sensor (VSS), oil pressure warning light . . . . . . . .41/14Instrument cluster, engine coolant temperature (ECT) gauge, tachometer, speedometer, generator (GEN) warning light . . . . . . . . . . . . . . . . . . . . . . . . . .41/15Instrument cluster, multi-function indicator (MFI), outside air temperature sensor,electronic power control (EPC) warning lamp . . . . . . . . . . . . . . . . . . . . . . . . . .41/16

1.8L - Engine - Motronic Multiport Fuel Injection (MFI)/110kW, code AWD,

from November 1999

No./Page

Notes

60

77

Glossary

Glossary

American Wire Gauge (AWG): The American standard for wire size, expressed in units from2 gauge to 22 gauge.

Central relay panel: A centralized location for relays and circuits in an automobile. Includescommon circuits used to provide battery power, ignition “ON”, and Ground to vehicle sys-tems.

Control Module: A transistorized, rather than analog, switching circuit that relies on one orinputs to control the switching of a logic circuit.

Current track number: A method of following circuits within Volkswagen wiring diagrams.The wiring diagram is numbered along the bottom of the page to aid in navigating betweendisconnected pages.

DIN (Deutsche Institut fur Normung) standards: German institute for standards thatestablishes guidelines for manufacturing and nomenclature.

Electric motor: A motor driven by electromotive force.

Fuse: A component installed in series with a circuit, designed to disrupt the circuit when car-rying more than its specified amperage. Fuses are placed in circuits to protect other compo-nents in the circuit from damage.

Ground: A wire connected to the vehicle's chassis (and therefore the Ground). This allowspower to be supplied by one insulated wire, while the chassis acts as the return path.

Internal conductors: Connections inside of a component, often not designated in the wiringdiagrams.

Load reduction circuit: A circuit designed to switch off high current electrical consumersduring starting to insure optimal available voltage supply to the starter. The term comes fromremoving the load of the consumers from the Ignition switch.

Metric wire sizes: The metric system for wire size, expressed in mm2. This designates thecross-sectional area of the wire. The wiring used in Volkswagen vehicles ranges from .35 to35 mm2.

Multi-point connectors: A connector installed in a wiring harness that allows the wiringharness to be detached from the component.

Potentiometer: see Rheostat

78

Relay: Component that uses a low current to switch a high current circuit.

Resistor: A component that creates a voltage drop in a circuit. Resistors can be used formeasurement of current flow, as well as to drop the applied voltage for certain consumers.

Rheostat: A resistor that varies its resistance based on a mechanical input.

Push-on connectors: See Multi-point connector.

Solenoid: Used to actuate other components, a solenoid consists of a coil of wire wrappedaround an iron core. When a current is passed through a wire, a magnetic field is induced.This magnetic "pull" is used to operate other components.

Switch: A component used to disrupt or redirect current flow.

Symbols: Graphical representations of electrical components in Volkswagen wiring dia-grams

Temperature dependent resistor: A resistor that varies its resistance with temperature.

Threaded Connectors: A connector consisting of a threaded stud to which other wiresattach. Often used in high Amperage circuits.

Vehicle Chassis: See Ground.

Welded Connectors: A connection inside of a component created by compressing severalwires together under high heat, partially melting the separate wires together.

X circuit: See Load reduction circuit.

Glossary

An on-line Knowledge Assessment (exam) is available for this Self-Study Program

You can find this Knowledge Assessment on your Certification Resource Center

at:

www.vwwebsource.com

From the vwwebsource.com homepage, do the following:

1. Click on the Certification tab 2. Click on “My Certification” tab 3. Click the Fulfill link next to this SSP 4. Click “Launch Assessment”

For assistance, please call:

Volkswagen Academy Concierge 1 – 877 – 791 – 4838

(8:00 a.m. to 8:00 p.m. EST) Or, E-Mail:

[email protected]

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jHow to ReadWiring Diagrams

Symbols, Layout and Navigation

Self-Study ProgramCourse Number 873003

Volkswagen of America, Inc.3800 Hamlin RoadAuburn Hills, MI 48326Printed in U.S.A.August 2001

how to read wiring diagrams - justanswer...j 2 20 t121/ 76 sw/ws 0,35 t121/38 e 45 e 227 ws 0,35...

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