Volkswagen 2004 Golf Service Training

The Golf 2004

Electrical system

Design and function

Self-study programme 319

Service Training

2

NEW Important

Note

This self-study programme shows the design and

function of new developments!

The contents will not be updated.

For the latest testing, setting and repair

instructions, please refer to the relevant

workshop literature.

S319_063

The most striking change compared with the previous model is the rear lighting of the Golf 2004.

The one-piece light unit, common on the previous model, has now been replaced by a two-piece light

unit. This is comprised of a separate independent light element in the side part and a fixed element in the

tailgate.

In this way, the car's relationship to the prestige Volkswagen models is made evident.

A bright and high quality appearance is achieved by day and by night by means of round elements,

comprised of several parts, located behind clear lenses.

3

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

LIN data bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Onboard power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Tyre pressure monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Convenience and safety electronics. . . . . . . . . . . . . . . . . . 42

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Test yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4

Introduction

Fitting locations

The onboard electrical system of the Golf 2004 is

similar to that of the Touran. Golf 2004 and

Touran vehic les are based on the same platform.

The onboard electrical system of the Golf 2004 is

of the decentral design. Distribution of the fuse

boxes and relay sockets in various locations

facilitates quick and precise fault diagnosis.

Fuse boxes and relay slots in vehicle electrical system

Electrics box, on left in engine

compartment

Pre-fuse box, on left in

engine compartment

5

Fuse box, on left in

dash panel

S319_001

Relay carrier of onboard power

supply control unit on left

under dash panel

Relay carrier, on left beneath

dash panel, above onboard

power supply control unit

6

The networking concept

Overview of networked control units

In order that data can be transferred without

conflict or interference between the individual

control units, these are connected together in

a network via various data bus systems.

The data bus diagnostic interface J533

(Gateway) provides an interface for the

following data buses:

-Drivetrain CAN data bus

-Convenience CAN data bus

-Infotainment CAN data bus

-Dash panel insert CAN data bus

-Diagnosis CAN data bus

S319_011

LIN data bus

Drivetrain CAN

data bus

Convenience

CAN data bus

Infotainment

CAN data bus

wire

LIN data bus

wire

Dash panel insert

CAN data bus

Diagnosis CAN

data bus

CAN data bus

Sensor

Introduction

In addition to the CAN data bus,

a number of electric components are

networked via the LIN data bus.

J220

NOx

J431

J503

R

J412

J345

J608

J525

J519

J136

J255

J364

R78

J386

J387

J388

J533

J285

J334

T16

J389

Communications

line

7

Key

DIgnition/starter switch

E221 Operating unit in steering wheel

G85 Steering angle sender

G273 Interior monitoring sensor

G384 Vehicle inclination sender

G397 Rain and light detector sensor

G419 ESP sensor unit

H8 Anti-theft alarm system horn

J104 ABS with EDL control unit

J136 Seat and steering column adjustment control

unit with memory

J217 Automatic gearbox control unit

J220 Motronic control unit

J234 Airbag control unit

J255 Climatronic control unit

J285 Control unit with display in dash panel insert

J334 Immobiliser control unit

J345 Trailer detection control unit

J364 Auxiliary heater control unit

J386 Driver door control unit

J387 Front passenger door control unit

J388 Rear left door control unit

J389 Rear right door control unit

J393 Convenience system central control unit

J400 Wiper motor control unit

J412 Mobile telephone operating electronics control

unit

J431 Headlight range control, control unit

J446 Parking aid control unit

J500 Power steering control unit

J503 Control unit with display for radio and

navigation

J519 Onboard supply control unit

J525 Digital sound package control unit

J527 Steering column electronics control unit

J533 Data bus diagnostic interface

J587 Selector lever sensors control unit

J604 Auxiliary air heater control unit

J608 Special vehicle control unit

J743* Direct shift gearbox mechatronics

NO

x

NO

x

sensor

RRadio

R78 TV tuner

T16 16-pin connector, diagnosis interface

*On direct shift gearboxes only

S319_008

G419

J217

J587

J104

J500

J234

E221

J446

J400

G397

J393

J604

G273 H8

G384

J527

D

G85

J743*

8

Control units and fitting locations

The adjacent illustration shows the control units

of the drivetrain CAN data bus and associated

fitting locations.

The data is transferred at a rate of 500 kbit/s.

Transfer is made via the orange/black CAN high

wire and orange/brown CAN low wire.

To guarantee data transfer without conflict or

interference, the CAN wires are twisted

together.

Introduction

Control units in drivetrain CAN data bus

Motronic control unit J220,

under plenum chamber cover

ABS with EDL control unit J104,

on right of bulkhead in engine

compartment

Airbag control unit J234,

beneath centre console,

on front of tunnel

9

S319_002

Headlight range control, control unit

J431,

on right of glove compartment

Data bus diagnostic interface J533,

beneath dash panel, above accelerator

pedal

Automatic gearbox control unit J217,

on left in wheel housing

Steering column electronics control

unit J527,

beneath steering column switch

10

Control units and fitting locations

The adjacent illustration shows the control units

of the convenience CAN data bus and

associated fitting locations.

The speed of data transfer is 100 kbit/s.

The data is transferred via the orange/green

CAN high wire and orange/brown

CAN low wire.

To guarantee data transfer without conflict or

interference, the CAN wires are twisted together.

Introduction

Climatronic control unit J255,

in centre console

Convenience system central control unit

J393,

on right beneath dash panel,

behind glove compartment

Steering column electronics control unit J527,

on steering column switch

The control units in the drivetrain CAN data bus

11

S319_004

Data bus diagnostic interface J533,

beneath dash panel, above accelerator

pedal

Onboard supply control unit J519,

under dash panel on relay carrier

Door control units J386, J387, J388, J389,

installed in doors

Trailer detection control unit J345,

in rear right side panel

Parking aid control unit J446,

in rear right side panel

12

Control units and fitting locations

The adjacent illustration shows the control units

of the infotainment CAN data bus and

associated fitting locations.

The infotainment CAN data bus transfers data

at a rate of 100 kbit/s. The CAN high wire is

orange/purple and the CAN low wire is

orange/brown.

To guarantee data transfer, the CAN wires are

twisted together.

Introduction

The control units in the infotainment CAN data bus

Mobile telephone operating electronics

control unit J412,

under right seat, beneath carpet covering on

right sill panel

Auxiliary heater control unit

J364,

on front right beneath wing

13

S319_005

Control unit with display for radio

and navigation J503

or Radio R,

in centre console

CD changer R41,

in centre console, beneath

front armrest

14

Dash panel insert CAN data bus

Information is exchanged via the dash panel

insert CAN data bus between the dash panel

insert control unit and the data bus diagnostic

interface. These are the only control units in this

data bus system.

Diagnosis CAN data bus

The transfer of data between the diagnosis tester

VAS 5051/5052 and the data bus diagnostic

interface is via the diagnosis CAN data bus.

Rate of data transfer

The rate at which data is transferred is

500 kbit/s for both CAN data buses.

Introduction

The control units in the dash panel insert CAN data bus and in the diagnosis

CAN data bus

Dash panel insert control unit J285

15

S319_006

Data bus diagnostic interface

J533,

beneath dash panel, above

accelerator pedal

16-pin connector,

diagnosis interface T16,

on left beneath dash panel

16

J400 G273 G384 H8

J519

G397

J527 E221 J393

Local Interconnect Network (LIN) defines a local

system in which all associated components within

a specific area are located.

● The local sub-system is a cost effective version

of CAN data bus.

● The defined consumer interface makes simple

exchange of the connectors possible.

● Bus connection in crash area

● Bus connection in critical safety areas

Information is exchanged in the LIN data bus

system via a master control unit and up to

16 slave control units.

Communication is initiated only by the master.

Slave control units cannot communicate

independently.

Several independent LIN data buses can be

installed in the vehicle with different functions.

Information is exchanged between the individual

bus systems via the master control units

connected to the CAN data bus.

LIN data bus

The LIN data bus as sub data bus system

S319_007

The LIN bus system

Key

E221 Operating unit in steering wheel

G273 Interior monitoring sensor

G384 Vehicle inclination sender

G397 Rain and light detector sensor

H8 Anti-theft alarm system horn

J393 Convenience system central control unit

J400 Wiper motor control unit

J519 Onboard power supply control unit

J527 Steering column electronics control unit

17

Master control unit

The control unit connected to the CAN data bus

takes on the master functions of the LIN data bus

system.

Tasks

● Conversion of local data bus messages to data

format of CAN data bus

● Monitoring of data bus conversion and rate of

data transfer

● Control of data transfer cycle

● Transfer of diagnosis data from slave control

units

Slave control unit

In the LIN data bus system, individual control

units, sensors or actuators can act as slave

control units.

The electronics integrated in the control units

evaluate the information, convert it into digital

information and send it, once the request has

been made, via the LIN data bus to the master

control unit.

Actuators are assigned their tasks by a signal,

which comes from the master control unit via the

LIN data bus.

Following interrogation of the master control

unit, the electronics integrated in the sensors

send the actual status to the master control unit,

in which a target/reference comparison is

carried out.

S319_068

The convenience system central control unit, illustrated, shows the wiring of the LIN and CAN data buses.

LIN data bus wires CAN data bus wires

18

Housed in the electrics box are the fuses for

components of the engine compartment and

the interior.

The connection between electrics box and

battery is very short (approx. 500 mm), which

enables use of the battery as a high frequency

filter between the consumers mounted directly

on the box.

Due to the increased number of fuses, the rating

of the fuses can be set to the individual

consumers.

Fitting location

The electrics box can be found on the left in the

engine compartment.

Onboard power supply

S319_031

Electrics box

The electrics box

19

The electrics box and pre-fuse box are located

in a housing in the engine compartment.

Electrics box

In addition to the fuses, the following relays can

also be found in the electrics box:

● Te rminal 1 5 voltage supply relay J329

● Te rminal 3 0 voltage supply relay J317

● Te rminal 5 0 voltage supply relay J682

● Fuel pump relay J17

(not diesel and FSI)

Pre-fuse box

In the pre-fuse box are fuses for:

● the alternator

● the electromechanical power steering

● the radiator fan

● power supply from terminal X

● the auxiliary heater

● terminal 30

● the rear battery (V6)

(to be introduced at a later stage)

S319_009

S319_010

20

Fitting location

On the left under the dash panel is a relay

carrier and the onboard supply control unit.

Relay carrier

Additional relays may be included on the relay

carrier depending on the equipment level.

On vehicles with electric seat adjustment, the

automatic safety device (thermal safety) is

installed here.

Relay carrier on onboard supply control unit

The following relays can be found on the

onboard supply control unit relay carrier:

● Power supply relay terminal 30G

● Termi nal 15 voltage supply relay

(on V6 only)

● Termi nal 75 voltage supply relay

● Heated rear window relay J9

● Horn relay J413

● Double washer pump relay 1 J729 (right)

● Double washer pump relay 2 J730 (left)

Onboard power supply

The relay carrier

S319_012

S319_065

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Volkswagen 2004 Golf Service Training

Volkswagen 2004 Golf Service Training

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