Windshield Wiper System

(1)

92 - 1

Windshield Wiper System

General information

The windshield wiper system is controlled by the Wiper Motor Control Module J400 which is integrated with Windshield Wiper Motor V .

To remove wiper blades, wiper arms must be set to "service/winter position" . The "service/winter position" is activated by operating windshield wiper lever in "touch sweep" position within 10 seconds after switching off ignition Owners Manual .

Note:

In order to prevent potential damage to wiper arms,

the windshield wipers will not function, or will cease functioning should the front hood be opened.

Additional information:

Owners Manual

Self Study Program - Course Number 892503 "VW 2006 GTI Introduction"

Wiring Diagrams Component Locations Caution!

When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications, as well as instructions on performing OBD program and electrical system function checks as specified in this Repair Manual 27-4, Battery,

disconnecting and connecting .

Page 1 / 15 Volkswagen Golf 5 - Windshield Wiper System

(2)

On Board Diagnostic (OBD), functions

Wiper Motor Control Module J400 and Vehicle Electrical System Control Module J519 have On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory.

Troubleshoot windshield wiper malfunctions by performing OBD program using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" .

Windshield wiper system, checking with Output Diagnostic Test Mode (DTM)

Windshield wiper system operation can be checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module J519 .

- Connect Vehicle Diagnostic, Testing and Information System VAS 5051/5052 97-1, VAS 5051 / 5052 - Select operating mode "Guided Fault Finding"

- Enter information as prompted and press ">" to confirm. After the DTC memory of all control modules has been checked:

- Use "Go to" button to select "Function / Component Selection"

- Select "Body (Repair Group 01; 27; 50-97)"

- Select "Electrical system int/ext (Repair Group 01; 27; 90-97)"

- Select "01 - Self-diagnosis"

- Select "Vehicle Electrical System Control Module" - Select "Vehicle Electrical System Control Module functions"

- Select "J519 - output DTM, sequential (Repair Group 97)"

- Press ">" to confirm.

- Select "1 - Output Diagnostic Test Mode (DTM) for an individual component"

- Select "Another actuator" until selection for "Wiper" is displayed

Page 2 / 15 Windshield Wiper System

(3)

- Follow tester prompts

Windshield wiper - Alternating Park Position (APP) function, deactivating

Special tools, testers and auxiliary items required

Vehicle Diagnostic, Testing and Information System

VAS 5051/5052 (VAS 5051 A version shown as example only)

Diagnostic cable VAS 5051/6A (or length

appropriate alternative)

Windshield wiper system is equipped with Alternating Park Position (APP) function).

Every other time the wipers are witched off, the APP function causes the wiper arms to move upward slightly from the lowest position, causing the wiper blade rubbers to "flip" or tilt in a manner that "alternates" from the

previous switch-off event.

APP function serves to increase wiper blade service life by alternating the wiper rubber contact angle at the windshield after use.

(4)

In order to install the crank on the wiper motor in the proper position, it is necessary to shut off the motor in the lowest park position. This is done by deactivating the APP

function in the coding of Wiper Motor Control Module J400 .

Note:

Activating APP function is not possible.

APP function is automatically activated after 100

wiping cycles. This applies to wiper motors in which the APP function was deactivated as well as for new wiper motors.

- Select "Coding control module for wiper electronics/deactivating APP"

- Press ">" to confirm. - Follow tester prompts

Windshield wiper assembly, removing and installing Caution!

When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications as well as instructions on performing

(5)

OBD program and electrical system function checks as specified in this Repair Manual 27-4, Battery,

disconnecting and connecting .

Torque wrench VAG 1331 (or equivalent 5 - 50

Nm)

Pry lever 80-200

Windshield wiper system, removing - preparation

- Deactivate APP function 92-1, Windshield wiper -

Alternating Park Position (APP) function, deactivating .

- Operate wipers briefly and allow to move to park position. Switch off ignition.

- Disconnect battery 27-4, Battery, disconnecting and connecting .

Note:

In order to be able to remove wiper frames with

linkages and wiper motor, wiper arms plenum chamber cover, and air guide trim must be removed.

(6)

Wiper arms, removing

- Pry off caps - arrows - from wiper arms.

- Loosen nuts - arrows - (do not remove).

- Lift wiper arm and loosen by gently rocking back and forth on shaft until felt to release.

- Remove nut and wiper arm.

Plenum chamber cover, removing

Plenum chamber cover, removing and installing

.

Repair Manual, Body Exterior, Repair Group 64,

Plenum chamber bulkhead trim, removing

(7)

- Remove screw - 1 - and nut - 2 - from trim - 3 - . - Remove trim - 3 - upward and from vehicle.

Wiper assembly, removing

- Disconnect electrical connection - 1 - .

- Remove screws - arrows - and swing wiper arms - 2 - upward and from vehicle.

Wiper motor, removing from frame

- Pry off ball head - arrow - of linkage - 1 - from motor crank using pry lever 80-200 .

(8)

- Remove nut - 1 - .

- Remove motor crank - 2 - from wiper motor shaft.

- Remove screws - arrows - and remove wiper motor with control module from wiper frame.

Wiper motor, installing in frame

- Insert wiper motor with control module into frame and secure with screws - arrows - .

- Tighten all fasteners according to values in table 92-8,

Wiper and Washer Systems, tightening torques .

- Place motor crank - 1 - onto wiper motor shaft. Distance

(9)

- a - to stop - 2 - must be 3 1 mm.

- Install crank to wiper motor shaft using nut - 3 - .

- Press ball head - arrow - of linkage - 1 - onto crank.

Windshield wiper assembly, installing

- Install wiper frame in reverse sequence. While installing, securing pin - 2 - of wiper frame must be inserted into grommet - 1 - on bulkhead.

- Connect electrical connection to wiper motor connection and engage it.

- Install air duct trim in reversed sequence. - Install plenum chamber cover

Repair Manual, Body Exterior, Repair Group 64, Gravity bonded windows; Plenum chamber cover, assembly

(10)

.

overview

- Reconnect battery 27-4, Battery, disconnecting and connecting .

- Install wiper arms 92-1, Wiper arms, removing and installing .

Wiper arms, removing and installing Removing:

- Wiper arms, removing 92-1, Wiper arms, removing . Installing:

Note:

Wiper arm nuts must only be torqued after wiper

blade park position is checked and adjusted.

Alternating Park Position (APP) function, deactivating if not

already done by this time.

- Operate wipers briefly, allow to run to park position and then switch off ignition.

- Mount wiper arms to wiper shaft and loosely install nuts - arrows - (do not tighten).

- Adjust wiper blade park position 92-1, Wiper blade

park position, checking and adjusting .

Wiper blade park position, checking and adjusting

(11)

Torque wrench VAG 1331 (or equivalent 5 - 50

Nm)

Alternating Park Position (APP) function, deactivating if not

already done by this time.

- Operate wipers briefly, allow to run to park position and then switch off ignition.

- If necessary, loosen wiper arm nut and adjust wiper blade park position as illustrated below:

Drivers side:

Distance - A - between tips of wiper lips and upper edge of cowl panel must be 10 mm.

- If necessary, set end position of windshield wiper blades by offsetting wiper arms.

Wiper arms, removing 92-1, Wiper arms, removing . - Tighten all fasteners according to values in table 92-8,

(12)

Passengers side:

Distance - B - between tips of wiper lips and upper edge of cowl panel must be 10 mm.

- If necessary, set end position of windshield wiper blades by offsetting wiper arms.

Removing wiper arms 92-1, Wiper arms, removing . Wiper arms, removing 92-1, Wiper arms, removing . - Tighten all fasteners according to values in table 92-8,

"Aero-wiper" blades, removing and installing Removing:

Note:

Driver and passenger wiper blades are different

lengths. Damage will result if wiper blades are interchanged.

To ensure proper wiper performance, only grab/lift

Aero-wiper blades at the mounting pivot on wiper arm when removing and installing.

To remove wiper blades, wiper arms must be set to

"service/winter position" . The "service/winter position" is activated by operating windshield wiper lever in "touch sweep" position within 10 seconds after switching off ignition.

- Set wiper arms to "service/winter position" by operating windshield wiper lever in "touch sweep" position within 10 seconds after switching off ignition.

(13)

- Fold wiper arm away from windshield.

- Turn wiper blade - 1 - on wiper arm until it reaches stop - arrow A - .

- Pull off wiper blade - 1 - from wiper arm pivot - arrow B - .

Installing:

- Slide wiper blade onto axle of wiper arm.

- Turn wiper blade on wiper arm axle until it reaches stop. - Carefully fold wiper arm back onto windshield.

Rain/Light Recognition Sensor G397 , removing and installing

In the event a Rain/Light Recognition Sensor G397 is bale to be removed intact from the bracket (for example, upon windshield replacement), it can be reinstalled. Ensure sensor is stored free from dust and debris, and that the contact pads are not damaged.

Trim removal wedge 3409

(14)

Removing:

Caution!

Switch off all electrical consumers.

Switch ignition off and remove ignition key.

- Remove interior mirror

.

Repair Manual, Body Interior, Repair Group 68, removing and installing interior mirror

- Disconnect electrical connection - 1 - from Rain/Lamp Recognition Sensor G397 - 2 - .

- Using trim removal wedge 3409 , pry Rain/Lamp Recognition Sensor G397 - 1 - from bracket - 2 - . Note:

While removing, the complete Rain/Lamp

Recognition Sensor G397 and not only the upper

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shell of the sensor must be pried off.

Installing:

Install in reverse order of removal, noting the following: Note:

Always clean windshield surface inside bracket for

Rain/Lamp Recognition Sensor G397 before installing.

Surface (connecting pads) of Rain/Lamp

Recognition Sensor G397 must not be soiled when installing.

If the surface (connecting pads) of Rain/Lamp

Recognition Sensor G397 is soiled, it can be potentially cleaned by "applying" and then "pulling off" one or more adhesive strips.

After installing Rain/Lamp Recognition Sensor

G397 , there must be no air bubbles between windshield and surface (connecting pads).

(16)

92 - 2

Windshield Washer System General information

Note:

Owners Manual

When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications as well as instructions on performing OBD program and electrical system function checks as specified in this Repair Manual 27-4, Battery,

disconnecting and connecting . On Board Diagnostic (OBD), functions

Windshield washer functions are controlled by the Vehicle Electrical System Control Module J519 which has On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory.

Troubleshoot windshield washer malfunctions by

performing OBD program using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" .

Windshield washer system, checking with Output Diagnostic Test Mode (DTM)

Windshield washer system operation can be checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module J519 .

Page 1 / 13 Volkswagen Golf 5 - Windshield Washer System

(17)

- Select "Another actuator" until selection for "Dual windshield washer pump" is displayed

Windshield washer system, component overview

Page 2 / 13 Windshield Washer System

(18)

Y-piece

Routes washer hoses to

washer jets

Right windshield washer jet Removing and installing

92-2, Windshield washer jets, removing and installing

Adjusting 92-2,

Windshield washer jets,

checking and adjusting

Left windshield washer jet Removing and installing

92-2, Windshield washer jets, removing and installing

(19)

Adjusting 92-2,

Windshield washer jets,

Angle coupling

Washer hose coupling to left

washer jet

Overview 92-6, Washer

Hose Couplings

Washer hose

Repairing 92-7, Washer

Hose Repair

Angle coupling

Washer hose coupling to

right washer jet

Hose Couplings

Washer fluid reservoir filling

tube

Removing and installing

92-2, Washer fluid reservoir filling tube, removing and installing

Washer fluid reservoir

connecting tube

removed and installed

together with reservoir

Washer fluid reservoir Removing and installing

92-2, Washer fluid reservoir, removing and installing

Windshield and Rear Window

Washer Pump V59

(20)

92-2, Windshield and Rear Window Washer Pump V59 , removing and installing

Angle coupling

Connection to Windshield

and Rear Window Washer Pump V59

Hose Couplings

Windshield Washer Fluid Level

Sensor G33

92-2, Windshield Washer Fluid Level Sensor G33 , removing and installing

Washer fluid reservoir, removing and installing

Washer fluid reservoir is made of three parts connected together. In order to guarantee the correct position of the parts to each other, make sure that the guides present on the individual components engage in each other while assembling.

1 - Filling tube

2 - Connecting tube (removed and installed together with

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reservoir)

3 - Washer fluid reservoir

Washer fluid reservoir filling tube, removing and installing

Removing:

- Pull off connecting tube - 1 - from washer fluid reservoir filler tube - 3 - .

- Remove screw - 2 - .

- Unclip hose bracket from filling tube - 3 - and remove. Installing:

Install in reverse order of removal, noting the following:

Locating pin on underside of filler tube must be inserted into hole - arrow - .

(22)

Connecting tube - 1 - and filling tube - 2 - must be joined so that the guides - arrows - engage in each other.

Washer fluid reservoir, removing and installing

Removing: Caution!

- Remove filling tube 92-2, Washer fluid reservoir filling

tube, removing and installing .

- Remove front bumper cover

.

Repair Manual, Body Exterior, Repair Group 63, Front bumper

Note:

In order to prevent interchanging washer fluid line

connections at Windshield and Rear Window

Washer Pump V59 , connections at pump and hose lines are color-coded. Hose connector pieces must be connected to the corresponding colored pump connections during installation.

(23)

- To release, twist securing clips at hose connections - 3 - and - 5 - and disconnect from Windshield and Rear

Window Washer Pump V59 - 4 - .

- If necessary, retain washer fluid using suitable container. - Disconnect electrical connection - 6 - at sensor - 7 - . - Pull Windshield and Rear Window Washer Pump V59 - 4 - upward from reservoir and disconnect electrical connection - 2 - .

- Where applicable, pull Headlamp Washer Pump V11 - 9 - upward from reservoir and disconnect electrical

connection - 10 - .

(24)

- Remove screws - arrows - and remove reservoir with filling tube and connector tube from vehicle.

Installing:

Install in reverse order of removal, noting the following: - Tighten all fasteners according to values in table 92-8,

- Where applicable, bleed headlamp washer system after completing assembly work 92-5, Headlamp washer

system, bleeding .

Windshield and Rear Window Washer Pump V59 , removing and installing

Note:

Depending on equipment, location of Windshield and

Rear Window Washer Pump V59 may differ slightly from illustrations. Removal is similar.

.

Note:

In order to prevent interchanging washer fluid line

connections at Windshield and Rear Window

Washer Pump V59 , connections at pump and hose lines are color-coded. Hose connector pieces must be connected to the corresponding colored pump connections during installation.

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- To release, twist securing clips at hose connections - 3 - and - 5 - and disconnect from Windshield and Rear

Window Washer Pump V59 - 4 - .

- If necessary, retain washer fluid using suitable container. - Remove Windshield and Rear Window Washer Pump V59 - 4 - upward from reservoir.

- Disconnect electrical connection - 2 - . Installing:

- Where applicable, bleed headlamp washer system after completing assembly work 92-5, Headlamp washer

system, bleeding .

Windshield Washer Fluid Level Sensor G33 , removing and installing

Note:

Depending on equipment, location of Windshield and

Rear Window Washer Pump G33 may differ slightly from illustrations. Removal is similar.

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.

- Disconnect electrical connection - 1 - at sensor - 2 - . - Pull Windshield Washer Fluid Level Sensor G33 - 2 - out from rubber grommet.

- If necessary, retain washer fluid using suitable container. Installing:

Install in reverse order of removal, noting the following: - Where applicable, bleed headlamp washer system after completing assembly work 92-5, Headlamp washer

system, bleeding .

Windshield washer jets, removing and installing Removing:

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- Press nozzle upward - arrow A - and pull out flap at rear - arrow B - .

- Disconnect hose - 1 - from washer jet and disconnect electrical connection - 2 - .

Installing:

- Connect electrical connection - 2 - and hose - 1 - to washer jet.

- Slide washer jet into installation opening until it engages audibly.

- Check jets and adjust if necessary 92-2, Windshield

washer jets, checking and adjusting .

Windshield washer jets, checking and adjusting Note:

In the event contamination in washer jet produces an

uneven spray pattern, remove washer jet and rinse it with water in the opposite direction of spray. It is permissible to further blow through in opposite direction of spray with compressed air. Do not use solid objects to clean washer jets

(28)

Repair Manual, Maintenance, Repair Group 00,

(29)

92 - 3

Rear Window Wiper System General information

Note:

Owners Manual

Rear window wiper functions are controlled by the Vehicle Electrical System Control Module J519 which has On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory.

Troubleshoot rear window wiper malfunctions by

Rear window wiper system, checking with Output Diagnostic Test Mode (DTM)

Rear window wiper system operation can be checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module J519 .

Page 1 / 9 Volkswagen Golf 5 - Rear Window Wiper System

(30)

- Select "Another actuator" until selection for "Rear window wiper" is displayed

Rear window wiper system, assembly overview

Page 2 / 9 Rear Window Wiper System

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1 - Cap

2 - Nut SW 13

12 Nm

3 - Wiper arm

Removing 92-3, Rear window

wiper arm, removing

Installing 92-3, Rear window

wiper arm, installing

Adjusting park position 92-3,

Rear window wiper park position,

4 - Gasket

5 - Rear window washer jet

Removing and installing 92-4,

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Rear window washer jet, removing and installing

Checking and adjusting 92-4,

Rear window washer jet, checking and adjusting

6 - Sealing ring

7 - Rear Window Wiper Motor V12

Rear Window Wiper Motor V12 , removing and installing

8 - M6 nut with washer

8 Nm

9 - Rubber ring 10 - Spacer

11 - "Aero-wiper" blade

Aero-wiper blade, removing and installing

Rear window wiper assembly, removing and installing

Special tools, testers and auxiliary items required Torque wrench VAG 1331 (or equivalent 5 - 50

Nm)

Rear window wiper arm, removing

- Switch ignition on and momentarily activate rear wiper in order to ensure wiper returns to park position.

(33)

Caution!

- Fold back cap - 1 - and unclip from wiper arm. - Loosen nut - arrow - (do not remove).

Caution!

Aero-wipers are very flexible. Grasp wiper blades only in area of wiper blade mount to lift them from rear window.

- Lift wiper arm and loosen by gently rocking back and forth on shaft until felt to release.

- Remove nut - arrow - and remove wiper arm.

Rear Window Wiper Motor V12 , removing and installing

Removing:

- Remove rear window wiper arm 92-3, Rear window wiper arm, removing

- Disconnect battery 27-4, Battery, disconnecting and connecting .

- Remove rear lid trim

.

Repair Manual, Body - Interior, Repair Group 70, Rear lid trim

(34)

- Release and disconnect electrical connection - 1 - . - Release and disconnect hose coupling - 2 - by pulling up on securing ring, and remove hose from motor.

- Remove nuts - arrows - . - Remove motor from rear lid. Installing:

Install in reverse order of removal, noting the following:

- Ensure correct fitting and orientation of gasket. Position mark - 1 - on gasket must align with mark - 2 - in rear window.

- Reconnect battery 27-4, Battery, disconnecting and connecting .

Rear window wiper arm, installing

- Switch ignition on and momentarily activate rear wiper in order to ensure wiper motor returns to park position.

Caution!

(35)

- Place wiper arm onto wiper shaft in the approximate park position and tighten nut - arrow - by hand.

Note:

Only tighten/torque nut - arrow - after adjusting rear

window wiper park position.

- Adjust rear window wiper park position 92-3, Rear

window wiper park position, checking and adjusting .

Rear window wiper park position, checking and adjusting

Torque wrench VAG 1331 (or equivalent 5 - 5- Nm)

(36)

Gap dimension - a - between wiper blade and lower edge of rear window must be 23 mm.

- If necessary, reset park position of rear window wiper by loosening arms 92-3, Rear window wiper arm,

removing .

"Aero-wiper" blade, removing and installing Caution!

Aero-wipers are very flexible. Grasp wiper blades only in area of wiper blade mount to lift them from rear window.

Removing:

- Fold up wiper arm.

- Release wiper blade mounting - 1 - from wiper arm in direction of - arrow - .

(37)

- Separate wiper blade - 1 - from wiper arm - arrow - . Installing:

Install in reverse order of removal, noting the following: - Engage wiper arm mounting fully onto wiper arm. - Carefully fold wiper arm/blade onto rear window.

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92 - 4

Rear Window Washer System General information

Note:

Owners Manual

Rear window washer functions are controlled by the Vehicle Electrical System Control Module J519 which has On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory.

Troubleshoot rear window washer malfunctions by

Rear window washer system, checking with Output Diagnostic Test Mode (DTM)

Rear window wiper system operation can be checked via output Diagnostic Test Mode (DTM) of Vehicle Electrical System Control Module J519 .

Page 1 / 5 Volkswagen Golf 5 - Rear Window Washer System

(39)

- Select "Another actuator" until selection for "Rear window washer" is displayed

Rear window washer system, component overview

Page 2 / 5 Rear Window Washer System

(40)

Coupling

Washer hose coupling

between passenger compartment and rear lid

Hose Couplings

Coupling

Washer hose coupling to

rear window washer jet

Hose Couplings

Rear window washer jet Removing and installing

92-4, Rear window washer

(41)

jet, removing and installing

Checking and adjusting

92-4, Rear window washer jet, checking and adjusting

tube

Angle coupling

Connection to Windshield

and Rear Window Washer Pump V59

Hose Couplings

Windshield and Rear Window

Washer Pump V59

92-2, Windshield and Rear Window Washer Pump V59 , removing and installing

Sensor G33

Washer hose

Hose repair 92-7, Washer

Hose Repair

(42)

Rear window washer jet, removing and installing Removing:

- Switch ignition on and momentarily activate rear wiper in order to ensure wiper returns to park position.

Caution!

- Fold back cap on rear window wiper arm.

- Use appropriate pliers to pull washer jet out from wiper shaft - arrow - .

Installing:

- Insert washer jet with (washer jet opening facing upwards) into wiper shaft as far as possible.

- Adjust washer jet 92-4, Rear window washer jet,

checking and adjusting .

Rear window washer jet, checking and adjusting

Repair Manual, Maintenance, Repair Group 00,

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92 - 5

Headlamp Washer System General information

Every fifth time the windshield washers are used, the headlamp washers are activated automatically when the windshield washer switch is operated and held for at least 1.5 seconds (headlamps must be turned on - low or high beam).

The activation time delay of the headlamp washer system can be adjusted between 0 and 12.75 seconds 97-5,

Headlamp washer system, adaptation .

After any disassembly/reassembly operations are performed to the headlamp washer system, the system must be bled and operation confirmed 92-5, Headlamp

washer system, bleeding .

Note:

Owners Manual

Wiring Diagrams Component Locations

On Board Diagnostic, functions

Headlamp washer system functions are controlled by the Vehicle Electrical System Control Module J519 which has On Board Diagnostic (OBD) capability. If malfunctions occur in monitored components, Diagnostic Trouble Codes (DTC) will be stored in memory.

Troubleshoot headlamp washer system malfunctions by performing OBD program using Vehicle Diagnostic, Testing and Information System VAS 5051/5052 in operating mode "Guided Fault Finding" .

Headlamp washer system, component overview

Page 1 / 9 Volkswagen Golf 5 - Headlamp Washer System

(44)

Right headlamp washer jet with

telescoping cylinder

Washer jet retainer,

removing and installing 92-5, Headlamp washer jet retainer, removing and installing

Washer jets, adjusting

92-5, Headlamp washer jets,

Telescoping cylinder,

removing and installing 92-5, Headlamp washer jet telescoping cylinder,

removing and installing

Left headlamp washer jet with

telescoping cylinder

Page 2 / 9 Headlamp Washer System

(45)

Washer jet retainer,

removing and installing 92-5, Headlamp washer jet retainer, removing and installing

Washer jets, adjusting

92-5, Headlamp washer jets,

Telescoping cylinder,

removing and installing 92-5, Headlamp washer jet telescoping cylinder,

removing and installing

Angle coupling

Washer hose coupling to left

washer jet

Hose Couplings

Hose

Angle coupling

Coupling to right washer jet

telescoping cylinder

Divides washer fluid line to

washer jets of headlamp cleaning system

Hose Couplings

T-piece

Divides washer fluid line to

washer jets of headlamp cleaning system

Angle coupling

tube

(46)

Angle coupling

Connection to Headlamp

Washer Pump V11

Hose Couplings

Headlamp Washer Pump V11 Removing and installing

92-5, Headlamp Washer Pump V11 , removing and installing

Sensor G33

Headlamp Washer Pump V11 , removing and installing Headlamp Washer Pump V11 is installed in washer fluid reservoir in right wheel housing.

Repair Manual, Body Exterior, Repair Group 63, Front

(47)

.

bumper

- Remove Headlamp Washer Pump V11 - 9 - upward from reservoir.

- Disconnect electrical connection - 10 - .

- To disassemble connecting tube - 8 - , pull securing clip at connection and pull connecting tube - 8 - from

Headlamp Washer Pump V11 . Installing:

- Bleed headlamp washer system after completing assembly work 92-5, Headlamp washer system, bleeding .

Headlamp washer jet telescoping cylinder, removing and installing

(48)

- Remove washer jets with cover - 1 - up to stop from bumper cover.

- Unclip cover - 1 - from retainers - arrows - on telescoping cylinder.

.

- Pull off securing clip - 4 - from hose connection.

- Disconnect hose connection from telescoping cylinder - 2 - .

- Remove screw - 1 - .

- Unclip telescoping cylinder - 2 - from bracket - 3 - . Installing:

Install in reverse order of removal, noting the following: - Washer hose to telescoping cylinder must be clipped into bracket.

(49)

- Bleed headlamp washer system after completing assembly work 92-5, Headlamp washer system, bleeding .

Headlamp washer jet retainer, removing and installing Removing:

Caution!

- Remove washer jet with cover - 1 - up to stop from bumper cover.

- Unclip cover - 1 - from retainer - arrows - .

(50)

- Lift lug - arrow - slightly and pull out washer jet holder. Installing:

Note:

With the lugs on the washer jet holder, it can be

adjusted how strongly the washer jet cover is fastened onto bumper cover. If washer jet holder is not slid in far enough, cover does not close. If washer jet holder is slid in too forcefully, cover and bumper cover may be deformed.

- Slide washer jet holder into telescoping cylinder until it engages.

- Install cover onto washer jet holder and let down telescoping cylinder.

- Check cover for correct seating on bumper cover. - Adjust cover if necessary by shifting washer jet holder into a higher or lower catch on the telescoping cylinder. - Bleed headlamp washer system after completing assembly work 92-5, Headlamp washer system, bleeding .

- Check washer jets for headlamp cleaning system and adjust if necessary 92-5, Headlamp washer jets,

checking and adjusting .

Headlamp washer jets, checking and adjusting

(51)

Repair Manual, Maintenance, Repair Group 00,

Headlamp washer system, bleeding

After any disassembly/reassembly operations are performed to the headlamp washer system, the system must be bled and operation confirmed.

Proceed as follows:

- Fill washer fluid reservoir. Warning!

Engage handbrake and ensure transmission is in range "P" .

- Switch on ignition. - Switch on headlamps.

- Operate windshield washer switch intermittently, with 3 - 5 impulses over a 3 second period (washer jet cylinder should momentarily engage/raise/lower).

- Repeat procedure until all air has been bled from system and washer jet cylinder engages/raises immediately and consistently.

(52)

92 - 6

Washer Hose Couplings

Several different designs of washer hose couplings are used in the windshield, rear window (where applicable) and headlamp washer systems.

Each coupling requires specific actions in order to disconnect and reconnect.

Windshield and rear window washer system

- Disconnect by pulling apart both halves of coupling. - Reconnect by pushing both halves of coupling together until felt and heard to engage.

- Disconnect by turning lock ring - 1 - through 90 - arrow - and then pulling apart both halves of coupling. - Reconnect by pushing both halves of coupling together and rotating locking ring - 1 - - arrow - until it engages.

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- Disconnect by lifting lock ring - 1 - approx. 1 mm - arrow - and then pulling apart both halves of coupling. - Reconnect by pushing both halves of coupling together and clipping locking ring - 1 - until it engages.

Headlamp washer pump

- Disconnect by depressing clip - 1 - in direction of - arrow - and then separating coupling from jet.

- Reconnect by keeping clip - arrow - depressed while pushing coupling onto jet until it engages.

- Check for proper fit by attempting to separate coupling without depressing clip.

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92 - 7

Washer Hose Repair

A concept has been developed to facilitate the repair of washer hoses.

Various individual hose connectors, adaptors, Ethylene Propylene Diene Methylene (EPDM) rubber hoses and shrink tubing will be offered as replacement parts. Note:

For part numbers, see Parts Catalog.

Repair parts will be available for both smooth and

corrugated hoses.

Smooth hoses, repairing

Smooth hoses with a diameter of 5 x 1 mm or 6 x 1 mm can be repaired with a EPDM repair hose section. - Trim and remove damaged sections of hose.

- Choose matching EPDM repair hose - 2 - and cable ties from Parts Catalog

- Insert hose - 1 - and - 3 - into ends of EPDM repair hose - 2 - to a depth of at least 10 mm - 2 - .

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- Secure with cable ties - 1 - as illustrated.

Corrugated hoses, repairing

Special tools, testers and auxiliary items required Hot air gun VAS 1978/14 or

Hot air gun kit VAS 5179 as illustrated

Note:

Area to be repaired must not be under stress of

stretching or bending.

If damaged area is longer than 20 mm, a new

section of corrugated hose must be obtained, and two sets of adapters inserted using following the following procedure.

- Trim and remove damaged sections of hose.

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- Choose matching repair adapters - 2 - and - 3 - and appropriate shrink tubing from Parts Catalog.

- Carefully warm end of hose - 1 - .

- Insert repair adapter - 2 - into hose - 2 - - arrow A - . - Carefully warm end of hose - 4 - .

- Insert repair adapter - 3 - into hose - 4 - - arrow B - .

- Trim shrink tubing sections so that corrugated hose is covered a minimum of 20 mm - dimension x - .

- Slide shrink tubing over corrugated hose, attach adapters together and secure repair with shrink tubing.

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92 - 8 Wiper and Washer Systems, tightening torques

Location / fastener Tightening torque

Wiper motor to wiper frame / bolts M6 8 Nm

Motor crank to wiper motor shaft / nut M8 18 Nm

Wiper assembly to body / bolts M6 8 Nm

Front wiper arm to wiper motor shaft / nuts M8 20 Nm

Washer fluid reservoir to body / bolts M6 8 Nm

Rear wiper arm to rear wiper motor shaft / nut M8 12 Nm Rear wiper motor assembly to rear lid / bolts M6 8 Nm Headlamp washer telescoping cylinder to front bumper cover / bolts 4.5 Nm

Page 1 / 1 Volkswagen Golf 5 - Wiper and Washer Systems, tightening torques