Category Archives: Electrical

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.

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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.

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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.

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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

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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)

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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)

 

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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)

 

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

 

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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.

 

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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.

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  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

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.

Adding switches to the blank switch covers in the centre console of the Volkswagen Golf and Jetta

Installing switches in the center console to utilise the blank spaces either requires purchasing the optional switch for that location from Volkswagen however these are a momentary switch, have different markings on them (W for example) and connectors for the switch are not readily available or fitting an aftermarket switch which looks out of place. This guide uses an off the shelf switch and no-one would know the switch is there unless they press the button. Whilst this guide is performed on a Golf Mark V the same blanks are used in the Golf Mark VI so the same switch can be used and the same principles can be applied to any other car with a similar setup.

As an alternative there is a company called CarStyle4You that sells buttons with different engraving that match the OEM buttons and they also sell suitable oem switches. See the end of this guide for their details and a few sample photos.

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(left: switches are both up, right: first switch is down)

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(left: both switches down, right: second switch is down)

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(left: both switches up, right: both switches down)

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(left: both switches down, right: both switches up)

The switch used here is a latching switch but momentary is also available. The switch illumination can be used but as the ends are removed you will get white light spilling out the sides so upgrading the internal light to a coloured LED gives a nice glow around the switch.

The switch used to be available from RadioShack in the US but they don’t seem to carry them anymore.

Jaycar (Australia and overseas)

SP-0742 Red
SP-0750 Red Momentary
SP-0752 Green
SP-0753 Green Momentary

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To allow the blank to fit and move freely the two sides of the switch around the cover of the switch must be removed, not that the base width must not be altered as it’s a perfect width for the centre console.

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Switch Blanks (Blind Covers)

Golf Mark V and VI

  • 1K0 959 623 C 3X1 (1K0959623C 3X1) – Passenger & Drivers Side
  • 1K0 959 623 D 3X1 (1K0959623D 3X1) – Middle

volkswagen_golf_switch_installation_09_switch_blank volkswagen_golf_switch_installation_10_switch_blank

volkswagen_golf_switch_installation_11_switch_blank volkswagen_golf_switch_installation_12_switch_blank

Remove the plastic in the switch as shown and roughen the surface on the bottom of the switch in preparation for gluing.

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Perform a test fitting of the switch and the switch blank to make sure it all fits together. Glue the cover from the switch and the switch blank together, roughen the surface of the switch cover and use a two part epoxy (5 min araldite or similar).

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Clip the switch and the switch blank together and test the operation.

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The finished switches ready for fitting to the centre console. When soldering the wire on keep the connections tight as the retaining nut has to fit over the soldered connections.

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Fit the switches and align them on the front (there is limited adjustment) and screw the retaining nut down tight. Once aligned use some two part epoxy (araldite or similar) to lock it tight and prevent the retaining nut from working it’s way loose. The wires have been taped up using Fabric Adhesive Tape for wiring looms and harnesses and connectors fitted around 300mm down to allow easy removal of the central console.

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CarStyle4You sell suitable engraved blanks and switches that match the OEM ones and can be illuminated. I may organise a few of these switches and post a separate guide/review as the quality looks top notch and well worth the money.

volkswagen_golf_switch_installation_carstyle4you_light_on_off volkswagen_golf_switch_installation_carstyle4you_vw_garage_open volkswagen_golf_switch_installation_carstyle4you_pursuit_mode

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CAN bus gateway removing, installing and upgrading – Volkswagen Golf

The role of the Gateway (also known as the Data bus diagnostic interface J533) is the exchange of data between the CAN data bus systems (‘powertrain CAN data bus’, ‘convenience CAN data bus’ and ‘infotainment CAN data bus’) and the conversion of diagnostic data from CAN data bus systems to K-cable and vice versa so the data can be used by vehicle diagnosis, testing and information systems like the dealer VAS tools and Vagcom/VCDS.

For various reasons including power drain issues with third generation head units or the addition of new unsupported modules the CAN bus gateway must be upgraded to a newer revision. This guide covers the replacement of the CAN bus gateway in a 2005 MY06 Volkswagen Golf GTI. The upgrade replaces the 1K0 907 530 E (1K0907530E) with a 1K0 907 530 AA (1K0907530AA).

This process works the same for most Volkswagen models.

1K0 907 530 E (1K0907530E)
Revision: 11

1K0 907 530 AA (1K0907530AA)
Revision: H16

Record current installation list and long coding

Take screen shots or make a note of your installation list in controller 19 – Can Gateway using Vagcom/VCDS. This step is critical unless you want to figure out what you had installed prior to the upgrade. Don’t be tempted to copy down the long code unless you are installing the exact same revision of gateway as different revisions have extra features.

volkswagen_can_bus_gateway_upgrade_installation_list_before_01

Whilst not essential it is worth taking a screen shot of the different screens in the long coding.

volkswagen_can_bus_gateway_upgrade_long_coding_before_01 volkswagen_can_bus_gateway_upgrade_long_coding_before_02

Removing and Installing the Gateway

Remove the key from the ignition or disconnect the car’s battery (the battery disconnect is optional but better safe than sorry)

Remove the footwell cover on the drivers side where the gateway is located – Volkswagen Golf footwell cover drivers side – Removal and  Installation.

The gateway can be in two locations on the Golf. One is above the accelerator pedal and the other is above the clutch pedal (if fitted). The clutch pedal location was used for the first year or so of production.

MY05 gateway location

volkswagen_golf_can_bus_replacement_01 volkswagen_golf_can_bus_replacement_02

Removing

  • Release the connector and pull the connector off the data bus diagnostic interface.
  • Press three securing pins together and push out of holes to release or the holder is hinged and release that.

Installation

  • Install in the reverse order of removal.

Reconnect the battery

MY06 onwards gateway location

volkswagen_gateway_data_bus_diagnostics_removal_01

Removing

  • Release the connector (1) and pull the connector off the data bus diagnostic interface (2).
  • Press securing pins (3) together (see arrows) and push out of holes to release.

Installation

  • Install in the reverse order of removal.

Reconnect the battery

Coding the new gateway

Using the screen shots and notes from earlier you can now recode the gateway. Below are screenshots showing the differences between the two gateways (old gateway on the left and new gateway on the right

volkswagen_can_bus_gateway_upgrade_installation_list_before_02 volkswagen_can_bus_gateway_upgrade_installation_list_after_02