4.6 Electrical system

General information

  • With the engine running, do not loosen or remove battery connection terminals.
  • Tow vehicle only with batteries connected.
  • Batteries should not be charged with a quick charger device unless they have been disconnected from the vehicle electrical system. Positive and negative terminal clamps must be removed.
  • Observe operating instructions!
  • Installation of electrical consumers.
  • Cables routed in the vicinity of exhaust systems must be shrouded to protect against fire.
  • Cables must be routed so there is no risk of abrasion.

 

Electromagnetic compatibilityIn vehicle electrical systems, electrical disturbances are caused by the individual consumers. At Volkswagen AG, the electronic components installed in the factory are checked in the vehicle for their electromagnetic compatibility.If retrofitting electrical or electronic systems, their electromagnetic compatibility should also be checked.The following industrial standards provide the necessary details:

  • DIN 40839
  • DIN 57879, part 3
  • VDE 0879, part 3
  • VWTL 965
  • VWTL 82066
  • VWTL 82166
  • VWTL 82366

Furthermore, EMC guideline EC 72/245 version 95/54 EC should be observed.

Further information is available from the department responsible.

 

Current draw of auxiliary consumersIf auxiliary consumers are installed retroactively, observe the following:

  • Make provision for batteries and alternators available as an option with higher output.
  • Do not connect additional consumers to fuses already assigned for another purpose.
  • Do not connect additional leads to leads already assigned for another purpose (e.g. with insulation cutting clips).
  • Install fuse protection for consumers with additional fuses of sufficient quantity.


Retroactive installation of auxiliary batteryAn auxiliary battery may only be installed in conjunction with an isolator relay and fuses in accordance with the charge current. Auxiliary batteries > 100 Ah must not be connected to the vehicle electrical system. This battery must be assigned exclusively to specific auxiliary consumers, such as auxiliaryheater, loading platform or electrical equipment in campers (refrigerator, etc.). If the auxiliary battery is installed in the passenger compartment, venting per central gas ventilation hose must be to the open.If an auxiliary battery is already installed in the base vehicle, no other auxiliary batteries may be connected in parallel.

Electrical wiring
If extending electrical leads, observe the following:

  • Use only FLKR leads with the same cross section and same colour as the series production leads.
  • The leads must be shrouded with an insulation hose (with a corrugated hose on HAZMAT vehicles).
  • Only attach genuine Volkswagen connectors to the ends of the wires.
  • Connection of the electrical lines may be only be carried out using splitter boxes.
  • ABS cables may only be extended using genuine Volkswagen cable sets.
  • If the structure of the vehicle is modified, routing of the electrical lines must be restored as closely as possible to the original condition.
  • If routing modifications become necessary, crossing over sharp edges and routing in enclosed cavities and in the vicinity of moving parts should be avoided.
  • Stressing the wiring harness by stretching must be avoided.
  • Grommets for cables that pass through equipment, junction boxes or similar components outside the passenger compartment must be watertight.


Risk of accidentBy incorrect intervention in electronic components and their software, these can no longer operate in the way intended. Due to networking of the electronics, other systems may also be affected that were not modified.Malfunctions in the electronics can seriously impair the operational safety of your vehicle.Have work or modifications to electronic components carried out by a qualified specialist workshop that has the necessary skills and knowledge to perform such tasks.Volkswagen recommends a VAG partner for this purpose.Work on safety-relevant systems, in particular, must only be carried out by a qualified specialist workshop.Some safety systems only work when the engine is running. When driving, do not switch the engine off.

Current draw
The connection of additional, electrical consumers must be by way of the terminal strip for ancillaries installed in the factory (PR no. UF3).

The terminal strip is attached on the inside to the driver seat box (front right as seen in direction of normal travel) and has three connections.

1. Term. D+ 12 V / 10 A
2. Term. 30 12 V / 25 A
3. Term. 15 12 V / 15 A

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of up-to-date data on body guidelines.December 2007

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