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Replacement batteries for the Volkswagen Golf, Jetta, Passat and others

Maverick — Wed, 15 Jun 2011 13:22:56 +0000

Replacement batteries for the Volksagen Golf, Jetta, Passat and others.

The PR Code can be found on a white sticker near the spare wheel.

PR Code: J1P – various models including Golf Mk V 1.4TSI 103kW (140PS)

OEM Varta 12V 44Ah 220A DIN 360A EN/SAE (360CCA)
1K0915105 (1K0 915 105)
(dimensions mm: 200W x 170L x 190H)

PR Code: J2S

OEM Varta 12V 51Ah 280A DIN
000915105DC (000 915 105 DC)
(dimensions mm: 200W x 170L x 190H)

PR Code: J1L
(superceded by J0N)

OEM Varta 12V 60Ah 280A Din ???A EN/SAE (???CCA)
000915105AC (000 915 105 AC)
(dimensions mm: 278W x 175L x 190H)

PR Code: J0N – various models including Golf Mk V GT 2.0 TDI 125kW (170PS)

OEM Varta 12V 61Ah 330A Din 540A EN/SAE (540CCA)
000915105DE (000 915 105 DE)
(dimensions mm: 200W x 170L x 190H)

PR Code: J0L – various models including Golf Mk IV, Golf Mk V GTI 147kW (200PS) & 169kW(230PS), B8 A4, C6 A6
(superceded by J1D)

OEM Varta 12V 70Ah 340A Din 570A EN/SAE (570CCA)
1J0915105AE (1J0 915 105 AE)
(dimensions mm: 278W x 175L x 190H)

PR Code: J1D – various models including Golf Mk V GTI 147kW (200PS) and some Mk VI models

OEM Varta 12V 72Ah 380A Din 680A EN/SAE (680CCA)
000915105DG (000 915 105 DG) – AUD $250
(dimensions mm: 278W x 175L x 190H)

PR Code: J2D- various Mk VI models

OEM Varta 12V 68Ah 380A Din ???A EN/SAE (???CCA)
000915105CC (000 915 105 CC)
(dimensions mm: 278W x 175L x 190H)

PR Code: J0R

OEM Varta 12V 80Ah 380A Din 640A EN/SAE (640CCA)
000915105AH (000 915 105 AH) – AUD $310
(dimensions mm: 315W x 175L x 190H)

PR Code: J1N – various models including Golf Mk V R32, Golf Mk VI R20

OEM Varta 12V 75Ah 420A Din 600A EN/SAE (600CCA)
000915105AH (000 915 105 AH) – AUD $310
(dimensions mm: 278W x 175L x 190H)

Varta Retail Battery Replacements

Varta have two levels of batteries for the Golf that suit. Note that the TDI has a bigger battery requirement.

GTI (Golf V)

563 400 061 3162 SILVER dynamic 63 610 (242mm x 175mm x 190mm)
577 400 078 3162 SILVER dynamic 77 780 (278mm x 175mm x 190mm)
560 408 054 3132 BLUE dynamic 60 540 (242mm x 175mm x 190mm)
574 012 068 3132 BLUE dynamic 74 680 (278mm x 175mm x 190mm)

(Lenth x Width x Height)

TDI (Golf V)

577 400 078 3162 SILVER dynamic 77 780 (278mm x 175mm x 190mm)
585 200 080 3162 SILVER dynamic 85 800 (315mm x 175mm x 175mm)
574 012 068 3132 BLUE dynamic 74 680 (278mm x 175mm x 190mm)
580 406 074 3132 BLUE dynamic 80 740 (315mm x 175mm x 175mm)

SILVER dynamic

This powerhouse of a battery is the premium option in the VARTA dynamic TRIO line-up. The SILVER dynamic delivers reliable energy supply even on vehicles with above average electrical consumers. With their superior cold start performance even in the most extreme conditions, and their huge reserve capacity, these batteries set standards which exceed the requirements of the international vehicle manufacturers themselves.

BENEFITS OF THE SILVER dynamic:
OE specification for high-performance, premium vehicles
Ideal for cars with lots of electrical equipment, whether factory or retro-fitted
The market’s premium battery option
Particularly suitable for diesels
Longer lifespan due to new PowerFrame technology

BLUE dynamic

The BLUE dynamic brand is already the most respected battery in the after market. Hardly surprising really, since it is built to meet or exceed the exacting specifications of the car manufacturers and offers superior starting, excellent safety features and unbeatable reliability.

BENEFITS OF THE BLUE dynamic:
For all classes of vehicles, original equipment specifications for today’s cars
Especially suitable for new and nearly new cars with standard level of electrical equipment
Most popular and trusted brand in the market place
Longer lifespan due to new PowerFrame technology

Volkswagen Golf Automatic Hatch Opening Updated

Maverick — Tue, 16 Nov 2010 21:57:54 +0000

The original Automatic Hatch Opening became less reliable over time as the springs compressed, this updated guide uses new struts from Skoda and bumpers from the Scirocco.

Parts required

2 x 6Y0 827 550 C (6Y0827550C) – Skoda Fabia gas struts
2 x 1K8 827 761 C (1K8827761C) – Scirocco bumpers
2 x 1J6 827 439 A ( 1J6827439A) – Strut ball pins

In Europe allow around €65 depending on the source, in the US the kit can be purchased from ECS Tuning. Australian pricing is around $300 through the dealerships so purchasing from Europe or the US is the way to go however freight can be expensive.

Tools required

VCDS or Volkswagen Dealer to perform the changes required
13mm spanner (an adjustable spanner can be used instead)
24mm spanner (an adjustable spanner can be used instead)
Small flathead screwdriver (#1 size)
3mm allen key
optional – Something to hold the hatch up (a broom, your head or similar)
optional – plastic safe grease

The parts required

Installation

The hatch needs to be supported for this part of the install so if you don’t have someone around to assist and you have a broom handy this can be placed in the handle area of the hatch and will hold the hatch up whilst you remove and replace the struts and ball pins as once a strut is removed it will fall on your head. If you don’t have a broom just make sure you have all the tools you require at hand and you can sit the hatch on your head whilst you work.

Removing the gas strut

Working on the hatch side insert the #1 flathead screwdriver into area shown (there is a small recess) and carefully lever the clip towards the end until it sits in place as shown in the second photo.

Pull the gas strut away from the pin to remove (a plastic trim removal tool can assist if it’s hard to remove).

The same process is repeated on the body side of the strut mounting.

Pull the gas strut away from the pin to remove (a plastic trim removal tool can assist if it’s hard to remove).

Replacing the ball pin

Using the 13mm spanner remove the ball pin from the hatch, this may be difficult to remove due to the paint holding it in place, using a sharp knife you could score the paint around the washer carefully to make it easier to remove and less prone to chipping or tearing at the paint on the hatch. I placed electrical tape on the spanner to make it a tighter fit and also stop the paint on the original ball pin from being damaged.

Unscrew the ball pin by hand once loose and clean up any raised loose pieces of paint around where the washer was sitting.

Install the new ball pin, you can see the new ball pin has a smaller washer but you can’t remove the washer from the other ball pin to use. To make it look like the old one you could spray paint the pin and the base.

The original ball pin and the one on the body had grease on them and I added a plastic safe grease to both after cleaning them.

Installing the new gas strut

Installation of the new gas strut is a reverse of the removal process. I found it easier to slide the clip back to allow the strut to clip on easier.

Removing the bumper

Using a 24mm spanner or adjustable spanner remove the bumper by rotating ~90 degrees and pulling it out.

Installing the bumper

The new bumpers are shown below, the lower one is adjusted to be fully extended and the upper one is fully retracted which is how it will be used on the Golf.

Insert the 3mm allen key into the end (make sure the bumper is locked first by pressing down on it and turning – the pictures above are of the bumper popped out and able to move up and down whereas the picture below shows the bumper locked into place) and turn counter-clockwise until it stops.

Push down on the bumper until it’s fully retracted and turn the allen key clockwise until it stops to lock it into position.

The bumper should now look like this, install into the opening, turn ~90 degrees to lock it into place and press downwards on the bumper and turn to unlock it so it is as shown in the second photo. The bumper can now be compressed and will assist in the initial opening of the rear hatch.

Coding changes

In VCDs/Vagcom change Byte 2 Bit 3 in the Central Convenience Controller 46.

Measurements (before and after)

Before: 65cm or 25.5″

After: 61.5cm or 24.25″

Comparison of parts

Bumper comparison

First photo is the bumper extended and the second locked in place to show it’s closed position (standard top / scirocco bottom).

As above, shows the standard bumper and the scirocco both extended and locked in position.

Ball Pin Comparision

(new one on the left, old one on the right)

The washer on the new one is 17mm whereas the old one is 20mm.

The height of the new one is 19mm whereas the old one is 30mm.

The size of the ball is identical when the paint thickness is taken into account.

Strut Comparison

The length of the shafts is pretty much identical at this end.

The thickness of the struts is different with the old one being 22.15mm and the new one being 19.20mm.

At this end the length of the struts is clearly different with the new one being 9.50mm shorter.

Change battery in folding key with remote control for Volkswagen Golf, Jetta, Passat, Rabbit and GTI

Maverick — Mon, 25 Oct 2010 09:55:55 +0000

Replacing the battery in the folding remote for Volkswagen Golf, Jetta, Passat, Rabbit, GTI and others using the same remote.

Battery required is a CR2032 lithium battery (3V with 225 mAh capacity)

(Assembly overview – battery for folding key with remote control)

1 – Key with variable code transponder

2 – Transmitter unit – upper part

3 – LED

When remote control is operated, this LED must flash briefly.
If LED does not flash during remote control operation, the battery is dead and must be renewed.

4 – Battery

5 – Transmitter unit – lower part

Removing battery

Step 1

Insert a screwdriver in slot between transmitter unit -1- and key -2-.
Twist screwdriver in -direction of arrow- to separate transmitter unit from key.

Step 2

Press transmitter unit -1- apart using profile section of key -2-.

Step 3

Unclip battery -1- from retainers -2- with a screwdriver in direction of -arrow-.

Installing

Note: Before installing battery, always press any key once to reset the transmitter unit to recognise the new battery.

Step 1

Lay battery -1- with positive terminal downwards in sender unit -2- (positive terminal is marked on housing).
Engage battery in transmitter unit by pressing down lightly.

Step 2

Fit cover to transmitter unit (do not damage seal).
Then clip transmitter unit to key.

Volkswagen Golf Mark VI Head Unit – Removal and Installation

Maverick — Wed, 20 Oct 2010 14:07:21 +0000

Tools required

Trim removal tools
Torx T-20 driver

Remove all CDs from head unit
Switch off ignition and all electrical consumers and remove ignition key

Removing

Using trim removal tool and carefully lever out centre console cover in area of -arrows- and remove cover.

Remove bolts -arrows- from radio or radio navigation system.
Pull radio or radio navigation system out of installation box far enough so as to allow access to the connectors on the back of the radio or radio navigation system.

Press together connector locking mechanism in direction of -arrows-.

Then swing locking bar up in direction of -arrow- and pull out connectors.

Release connectors -arrows- on aerial connections and pull these out.

Installing

Installation is a reverse of the removal process.
Never press the display or buttons whilst fitting the head unit as this may damage the unit.
A new head unit requires the anti-theft code to be entered.
Coding of the car is required to accept the new head unit.

Volkswagen Golf Middle A-Pillar Trim – Removal and Installation

Maverick — Wed, 20 Oct 2010 12:04:10 +0000

Applies to Mark V and Mark VI both left and right sides

Remove Volkswagen Golf dash panel end trims

Removing

Remove dash panel end trim
Pull upper part of trim out from body mount -A-
Pull trim upwards from A-pillar lower trim -B-

Installing

Install in the reverse order of removal and ensure the trim is positioned in the door seal beading.

Volkswagen Golf Dash Panel End Trim – Removal and Installation

Maverick — Wed, 20 Oct 2010 11:53:03 +0000

Applies to Mark V and Mark VI

Lever dash panel end trim by inserting trim removal tool as shown.

Body Panel Gaps and Shut Lines – Volkswagen Golf Mark V

Maverick — Wed, 20 Oct 2010 11:35:02 +0000

Body panel gaps and shut lines – Volkswagen Golf Mark V

To adjust or check gaps use tool setting guage 3371, gaps are in millimetres

Body – Front

Body – Centre
(2 door model gaps and shut lines – door to side panel is 3.5mm +-0.5mm)

Body – Rear

Rear seat noise (rattling, clicking and squeaking) in Volkswagen Golf

Maverick — Mon, 31 May 2010 03:26:02 +0000

A common source of noise (rattling, clicking and squeaking) is the rear seat latches, when the seats move the lock mechanism moves around on the latch and makes a noise. You could try tapping them with a hammer from above to bend the latch slightly downwards but this doesn’t seem to fix the problem in most cases.

To test to see if it is the latches making the noise drive around with the seats lowered. If it is the latches the simplest fix is to wrap some electrical tape around the latch where the lock contacts it to stop the movement and remove the metal on metal noises. The fix should last for around 50 operations of the rear seats before you have to reapply the tape and only takes a few minutes and a roll of electrical tape (3M Temflex 1610 was used but any quality brand is ok, avoid cheap brands) in any colour except for body colour or black as you won’t be able to see if parts of the tape are stuck in the mechanism or if the tape requires replacing.

Lower the rear seats
Clean the latch with a suitable cleaner (99.7% Isopropyl alcohol or similar is suitable)
Wrap 14cms of 3M Temflex 1610 electrical tape (or equivalent) which will give you six full wraps.
Close the rear seat

(the latches after cleaning, you can see where the lock mechanism has been contacting on the first photo)

(the latches after applying the tape, this is the area in which the lock mechanism contacts the latch)

(this is the tape after many uses, it should be replaced before it looks like this – I had started to peel it back prior to the photos)

(check the lock mechanism for any large stray pieces of tape that might cause problems with the operation)

Fitting GTI stainless steel seat inserts to the Volkswagen Golf GTI

Maverick — Wed, 26 May 2010 12:04:25 +0000

Volksagen Golf GTI stainless steel seat inserts are available on ebay for around USD$25 for a set of two (search for “gti insert” or similar).

Fitting is easy, twist them slightly to make them sit flush in the handle, clean out the insert position in the handle with a suitable cleaner and apply some clear silicone (sparingly) to the rear of the badge.

Fitting the OSIR O-Rest Volkswagen Golf GTI RHD dead pedal/footrest

Maverick — Tue, 25 May 2010 15:12:21 +0000

The RHD Volkswagen Golf GTI has a plain plastic dead pedal/footrest unlike the LHD models that get a stainless steel one to match the pedals. OSIR have a footrest that fits the Mark V and Mark VI GTI’s available for under USD$80 and is easily fitted with double sided tape to bulk out the rear and three screws into the soft plastic.