Category Archives: DIY

Oil Change Tools for the Volkswagen BPG, BPY, BWT and other FSI engines

Volkswagen have a Spezialwerkzeug (Special Tool) for draining oil from the oil filter housing for the following models with FSI engines.

The Volkswagen oil filter housing drain tool is part number T40057 and suits 2006-2008 VW/Audi models with the 2.0L Turbo (engine codes; BPG, BPY, BWT), the 2005.5 – 2011 2.5L inline 5 cyl VW engine and the 2012 onwards VW Golf R.

Engine Codes

BPG, BPY and BWT
CCTA
CBFA
CAEB
CALA
CBRA
CETA
CBPA
CDLC, CDLF, CDLG and CRZA (Golf R 2012 onwards)

Genuine Tools

Assenmacher VW & Audi Oil Filter Drain Tool T40057

volkswagen_oil_change_tool_assenmacher_t40057_2 volkswagen_oil_change_tool_assenmacher_t40057_1

Amazon US ship this wordwide here.

Also the Matra T40057

Aftermarket Tools

Motivx Tools VW & Audi Oil Filter Drain Tool MX2340

volkswagen_oil_change_tool_motivx_1 volkswagen_oil_change_tool_motivx_3 volkswagen_oil_change_tool_motivx_2 volkswagen_oil_change_tool_motivx_5 volkswagen_oil_change_tool_motivx_4

Amazon US ship this worldwide here.

 

MobileFaction VW & Audi Oil Filter Drain Tool

volkswagen_oil_change_tool_mobilefaction_1 volkswagen_oil_change_tool_mobilefaction_2 volkswagen_oil_change_tool_mobilefaction_3

Made in the USA from cast resin.

MobileFaction ship this worldwide here.

Schwaben VW & Audi Oil Filter Drain Tool 000930SCH01A

volkswagen_oil_change_tool_schwaben_1 volkswagen_oil_change_tool_schwaben_2 volkswagen_oil_change_tool_schwaben_3

ECS Tuning ship this worldwide here.

Adding a DAB/DAB+ aerial to the Volkswagen Golf Mark V & VI, Jetta, Passat and others

Adding a DAB/DAB+ aerial to the Volkswagen Golf Mark V & VI, Jetta, Passat and other models can be achieved in four ways.

  • Glass mounted stick on aerial <coming soon>
    (Surface mounted or external)
  • Using the OEM method of the rear window aerial <coming soon>
  • Roof mounted <coming soon>
    (Replacing the roof mounted aerial)

 

Adding a DAB/DAB+ aerial – DIY

Adding a DAB/DAB+ aerial – DIY is useful if you haven’t decided how to add on DAB/DAB+ support to your vehicle.

See the main article to see the other options – Adding a DAB/DAB+ aerial to the Volkswagen Golf Mark V & VI, Jetta, Passat and others The connector on the rear of the head unit is a Fakra Black Type A plug so a Fakra Black Type A jack (or a universal one) is required on the DIY aerial, see the this article for further information on Fakra connectors – FAKRA (SMB) Connector Information and Specifications.

In this example I’ve used a spare RNS 510 GPS aerial with RJ174 coax, cut off the GPS aerial and removed the Fakra Blue Type C jack housing from around the connector.

volkswagen_dab_aerial_diy_01

 

 

 

 

 

 

Construction is simple.

1. Strip away the outer insulation and the braided shield from the first 300mm.

volkswagen_dab_aerial_diy_02

 

 

 

 

2. Strip away the outer insulation on the next 230mm.

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3. Make a coil after the braided section of 50mm in diameter and secure with some electrical tape or similar.

volkswagen_dab_aerial_diy_06

 

 

 

 

 

 

 

 

 

4. Add electrical tape or heatshrink to the end of the braided section as shown and the end of the aerial to enable it to be hung up.

volkswagen_dab_aerial_diy_04

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This aerial is best suited to a static environment such as a house but works quite well in a vehicle in various locations such as behind the front seats and the b-pillars.

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Original concept was from here – http://www.audiobritain.co.uk/DAB.html

FAKRA (SMB) Connectors, Cables and Adapters

Fakra Cables

Volkswagen sell Fakra cables pre made in various lengths, the connectors fitted to these cables are a Type Z(Neutral Key Code) that works with the majority of Fakra connectors – see FAKRA (SMB) Connector Information and Specifications for further detail. To create an extension lead add the 0.3m Fakra Plug (Male) to Fakra Plug (Male) – 000 098 692 (000098692).

Fakra Jack Female to Fakra Jack Female

volkswagen_fakra_cable_000098650

0.3m Fakra cable – 000 098 650 (000098650)
0.5m Fakra cable – 000 098 651 (000098651)
1.0m Fakra cable – 000 098 652 (000098652)
1.5m Fakra cable – 000 098 652A (000098652A)
2.0m Fakra cable – 000 098 653 (000098653)
2.5m Fakra cable – 000 098 653A (000098653A)
3.0m Fakra cable – 000 098 654 (000098654)
3.5m Fakra cable – 000 098 654A (000098654A)
4.0m Fakra cable – 000 098 655  (000098655)
4.5m Fakra cable – 000 098 655A (000098655A)
5.0m Fakra cable – 000 098 656 (000098656)
5.5m Fakra cable – 000 098 656A (00009865Â)
6.0m Fakra cable – 000 098 657 (000098657)
7.0m Fakra cable – 000 098 658 (000098658)

 

Fakra Adapter Cables (300mm)

volkswagen_fakra_adapter_000098672

Fakra Plug (Male) to BNC (Male) – 000 098 672 (000098672)

 

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Fakra Plug (Male) to FME (Male) – 000 098 678 (000098678)

 

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Fakra Plug (Male) to SMA (Female) – 000 098 686 (000098686)

 

volkswagen_fakra_adapter_000098692

Fakra Plug (Male) to Fakra Plug (Male) – 000 098 692 (000098692)

 

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Fakra Plug (Male) to FME (Female) – 000 098 693 (000098693)

 

volkswagen_fakra_adapter_000098696

Fakra Plug (Male) to ISO Radio – 000 098 696 (000098696)

 

volkswagen_fakra_adapter_000098697

Fakra Plug (Male) to RAKU 2/RAKU II (Male) – 000 098 697 (000098697)
RAKU 2/RAKU II is the standard connector on the AM/FM roof mounted Aerial on the Golf MkV and MkVI.

 

volkswagen_fakra_adapter_000098698

Fakra Plug (Male) to RAST 2/RAST II (Female)- 000 098 698 (000098698)
The RAST 2/RAST II is the matching female connector for the RAKU 2/RAKU II.

 

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Fakra Plug (Male) to SMB (female) – 000 098 700 (000098700)

 

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Fakra Plug (Male) to Fakra Jack (Female) – 000 098 703 (000098703)

FAKRA (SMB) Connector Information and Specifications

FAKRA Connectors are designed for automotive applications and are based on the SMB connector interface and comply with the standard for a uniform connector system established by FAKRA (FACHARBEITSKREIS AUTOMOBIL – German group of experts from vehicle manufacturers and equipment suppliers). Due to their special standard locking system FAKRA connectors fulfill the high functional and safety requirements of today’s automotive industry and are specified for 6 GHz in 50 omh or 60 ohm. These connectors are commonly used in GPS antenna, Engine management system, Analog/Digital radio, Auxiliary heating, TV/Video-displays, Antenna, Distributor box, Accident data analysis, Mobile phone, Remote control keyless entry, Distance control, Air pressure control, and Navigation systems.

The connectors are equipped with a standardized coding system which permits easy and fast assembly using fourteen possible coding options. The locking system has primary and secondary locking to prevent inadvertent detachment.

The FAKRA standard is described today in the DIN 72594-1 / ISO 20860-1 and harmonized with the USCAR-17 standard and the goal is to transfer the DIN and USCAR standard into an international ISO standard. USCAR-17 is meanwhile replaced by ISO 20860-1 and the same will happen with DIN 72594-1.

volkswagen_fakra_plug_jack

 

 

 

 

 

 

 

 

  1. Sophisticated mechanical and color coded system with 14 different codes
  2. Continuous strip mounted, stamped and formed center contacts ensure efficient automatic assembly
  3. High mounting security:
    1. Pre-assembling locking features ensures correct position of the coaxial insert in the coded housing
    2. Secondary locking feature prevents incorrect mating
    3. Secure primary locking system between plug and jack with tactile and audible locking mechanism
    4. Protection frame and protection strip protect against accidental demating
  4. Coaxial insert and cable can be rotated freely 360° in coded housing
  5. Secure secondary locking with high axial retention force of the coaxial insert in the coded housing
  6. Shock and vibration proof housing protects coaxial insert
  7. Cable types with fixing groove for chassis mounting
  8. Special shape of inner contact ensures tilt resistant PCB mounting

 

volkswagen_fakra_plug_dimensionsFAKRA Plug (male)

  • Snap-on coupling
  • Plastic housing covered (14 color options)
  • Six slots radically spaced outer contact inside shell
  • Female center contact
  • Insulator surrounds female center contact wholly for 50 ohm
  • An air gap between female center contact and outer contact for 75 ohm Fakra male

 

 

FAKRA Jack (female)volkswagen_fakra_jack_dimensions

  • Snap-on coupling
  • Plastic housing covered (14 color options)
  • A trough for mating captive after a smooth area of dia. 3.7mm, 3.0mm length from mating end
  • Male center contact
  • Insulator nestles up throughout against outer contact. An air gap between insulator and male center contact for 50 ohm Fakra female
  • Reducing insulator amount. An air gap between male center contact and outer contact for 75 ohm Fakra connector

Plug and Jack Keying Options

Plug Keying Options

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Jack Keying Options

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Mechanical and Colour Coding

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Commonly used Volkswagen Fakra connectors

A-Black – DAB/DAB+(RNS310 DAB/RNS510 DAB)

B-White – DAB/DAB+ with active power

C-Blue – GPS (RNS2-MFD2/RNS510-MFD3/Skoda Columbus/Audi RNS-E/Audi MMI)

Further information on Connectors, Cables and Adapters can be found in this post – FAKRA (SMB) Connectors, Cables and Adapters

Volkswagen wire and cable specifications

An automotive wiring harness employs wires and cables. Each is made up of at least seven conductor strands (A), and
covered with an insulating material (B).

Within Volkswagen, wire and cable are classified in three general categories, and then specified according to size, type of insulation, and color.

 

 

 

 
Wires
Wires are stranded conductors ranging in size from 0.35 mm2 to 6.0 mm2 (approximately 22 to 9 gage (AWG)) that
make up most of a vehicle’s wiring harness. Smaller sizes save cost and weight. The larger sizes accommodate higher current loads with less resistance.

Wire larger than 6 mm2 (0 gage (AWG) is generally considered “cable.”

Wire size
Wire size (cross-sectional area) is the primary factor that will determine the current-carrying capacity of a conductor. Standard sizes differ slightly, depending on which measuring standard is used.

Volkswagen uses wire and cable that is manufactured according to the German industrial or “DIN” standards. Wire size is defined by cross-sectional area, and is measured in circular mils (mm2). As in the example shown, “0.75 mm” refers to the area (0.75 mm2), not the diameter.

Sizes of wire and cable originating in North America are described according to the American Wire Gage (AWG) standard. The standard wire sizes in both systems are roughly equivalent.

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

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

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

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

Tools required

  1. Trim removal tools
  2. 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.