Category Archives: Issues and Problems

Volkswagen Golf Mk7 Airconditioner Drain Hose Incorrectly Installed until June 2013 including Audi A3 and Seat Leon

Over 300,000 Volkswagen Golf Mk7 manufactured until June 2013 may have a problem with the Air Conditioner drainage hose being installed incorrectly which leads to water accumulating in the passenger foot-well. As of September 2013 only around 50 cases of this occurring have been identified.

Condensation that collects on the evaporator is normally discharged to the outside via a small hose on the firewall.

This problem also affects the Audi A3 and Seat Leon.

source: http://www.autobild.de/artikel/vw-golf-vii-skandal-im-dauertest-4362680.html

Volkswagen Golf Mark V & VI GTI, R32 and Bluemotion Wheel Alignment Specifications

Suits PR numbers: 2UA, 2UC, G02, G05, G07, 2UC, 2UB, G08, G11, G09, G04/2UC

These specifications apply to all engines.

The ride heights shown in the table refer to
dimension -a-.
Standard running gearSports running gear except 18"Sports running gear with 18" wheelsHeavy-duty running gearSports running gear GTISports running gear GTI US versionSports running gear R32BlueMotion
PR numbers2UA2UCG02, G05, G07, 2UC2UBG08G11G09G04/2UC
Front axle
Total toe (without load)10' +/- 10'10' +/- 10'10' +/- 10'10' +/- 10'10' +/- 10'10' +/- 10'10' +/- 10'10' +/- 10'
Camber (in straight-ahead
position)
-30' +/- 30'-41' +/- 30'-41' +/- 30'-14' +/- 30'-44' +/- 30'-30' +/- 30'-43' +/- 30'-41' +/- 30'
Maximum permissible
difference between sides
max. 30'max. 30'max. 30'max. 30'max. 30'max. 30'max. 30'max. 30'
Toe-out on turns 1) at 20° left
and right lock
1°38' +/- 20'1°40' +/- 20'1°40' +/- 20'1°38' +/- 20'1°22' +/- 20'1°38' +/- 20'1°20' +/- 20'1°40' +/- 20'
Caster7° 34' +/- 30'7° 47' +/- 30'7° 47' +/- 30'7° 17' +/- 30'7° 47' +/- 30'7° 34' +/- 30'7° 47' +/- 30'7° 47' +/- 30'
Maximum permissible
difference between sides
max. 30'max. 30'max. 30'max. 30'max. 30'max. 30'max. 30'max. 30'
Ride height382 +/- 10 mm367 +/- 10 mm367 +/- 10 mm402 +/- 10 mm360 +/- 10 mm382 +/- 10 mm362 +/- 10 mm367 +/- 10 mm
Rear Axle
Camber-1° 20' +/- 30'-1° 20' +/- 30'-1° 45' +/- 30'-1° 20' +/- 30'-1° 45' +/- 30'-1° 20' +/- 30'-1° 45' +/- 30'-1° 20' +/- 30'
Maximum permissible
difference between sides
max. 30'max. 30'max. 30'max. 30'max. 30'max. 30'max. 30'max. 30'
Total toe (At specified camber)+10' +/- 12,5'+10' +/- 12,5'+10' +/- 12,5'+10' +/- 12,5'+10' +/- 12,5'+10' +/- 12,5'+10' +/- 12,5'+10' +/- 12,5'
Maximum permissible deviation from direction of travelmax. 20'max. 20'max. 20'max. 20'max. 20'max. 20'max. 20'max. 20'
Ride height380 +/- 10 mm365 +/- 10 mm365 +/- 10 mm400 +/- 10 mm365 +/- 10 mm380 +/- 10 mm360 +/- 10 mm365 +/- 10 mm

1) Toe-out on turns can be displayed as a negative value on the wheel alignment computer, depending on the manufacturer.

Mark VI specifications differ with +/- 7mm for ride height

 

 

 

Volkswagen RNS 510 Backlight Dim after upgrading Firmware

After upgrading the RNS 510 to a higher version of firmware (3810 or higher) from revision C or earlier hardware running software 2840 or earlier the backlight may stop working after the gateway update and subsequent reboot. The screen can still be viewed with some additional light.

This recovery cd is based on the 2760 firmware but can be used to recover RNS 510’s running any version. Insert the media into the RNS 510 and start a new SWL process by pressing Setup + Eject +Info/Mic (top right hand button next to the DVD slot). It will attempt to restore a new SWL process and will enable it to boot up. There may be a problem with the RVC not working after this however and if this occurs and you want that to remain working you will need to flash an older version.

Download Location

File: http://www.megaupload.com/?d=VD5REKW1 (filename: 2760_ogw.rar containing 2760_ogw.nrg of size 482,285,686)

Install drainage for the Golf Mark VI Rear View Camera (RVC) installed in a Golf Mark VI

This guide is just one of the steps to installing a Golf Mark VI RVC into a Golf Mark VI – Installing a Golf Mark VI Rear View Camera (RVC) into a Golf Mark VI.

The Volkswagen RVC Camera from the Mark VI has a drain hole under the camera in the housing and this does build up a substantial amount of water under the right circumstances, I found around a litre of water in the base of the hatch after a downpour and when the hatch was opened in ran down inside the area around the rear window. There are two problems with drainage into the rear hatch and one is that many Golfs have all three drainage holes plugged and painted over and the other is that not all water can drain but instead sits in the seam at the bottom of the hatch until the rear hatch is opened.

volkswagen_rvc_drainage_drain_under_camera volkswagen_rvc_drainage_drain_under_camera_inside

photos: the drainage hole at the base of the camera and the exit point under the camera.

I removed one of the drainage plugs in the middle and whilst it stopped the buildup of excess water I had concerns about the rear hatch long term especially when so much water can make it’s way inside the hatch. The Mark VI has a tube that drains to the outside and that’s what I’ve done here.

volkswagen_rvc_drainage_tube_original_install_01 volkswagen_rvc_drainage_tube_original_install_02

photos: original drain tube installed and drain plug removed.

volkswagen_rvc_drainage_drain_plug_removed volkswagen_rvc_drainage_drain_plug_installed

photos: drain plug removed and drain plug still in place (left side of car)

Drain Tube

volkswagen_rvc_drainage_mark_6_factory_installed_01

photo: drain tube from a factory fitted RVC fitted to mark 6 GTI

Fitting the tube

After the drain plug has been removed push the tube in.

volkswagen_rvc_drainage_fitting_the_tube_01

The tube fits in under the lip on the bottom of the hatch so will require some jiggling around to force it under.

volkswagen_rvc_drainage_fitting_the_tube_02

Connect the clear tube to the drain above it.

volkswagen_rvc_drainage_fitting_the_tube_03

(note some of the photos above are from a Mark V that has a slightly different setup)

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.

Adjusting operation of the RegenLichtSens (Rain Light Sensor)

Adjusting the operation of the RegenLichtSens (RainLightSensor) is possible through Vagcom/VCDS or the VAS tools that Volkswagen dealers use however adjustments do not make a large difference in the operation of the sensor especially where you have the standard green glass.

Using Vagcom/VCDS open controller 9

Select the dropdown box and select option 2

Select config helper (may require version 10 of VCDS)

Light activation threshold can be adjusted here along with Highway light function (see Volkswagen Golf Auto Headlights above 140kph) and Rain Closing (see Volkswagen Golf Auto Rain Closing Windows and Sunroof)

Light sensor correction.

Rain sensor correction.

Volkswagen Golf, GTI, Passat, Jetta, EOS, Rabbit and Tiguan Air Conditioner Compressor Failure

Air conditioner does not work, noises from engine compartment

Volkswagen Technical Product Information # 2023580/1
Repair Operation # 87 34 01 99
Release Date: 29-Jun-2010

Problem

Air conditioning does not work.

Noises from the engine compartment.

Background

Pulley bolt works it’s way free from compressor shaft creating noise and eventually failure of the compressor.

Only Delphi Compressors are affected, optimised Delphi compressors fitted from August 2008.

The refrigerant circuit does not need to be flushed as the damage to the compressor is external.

Diagnosis

Check the connection between the pulley and the compressor shaft while they are fitted:

  • The cooling performance check shows no pressure increase, although the refrigerant circuit is correctly filled and the control valve current is about 0.8A.
  • The mounting bolt of the pulley has visibly wandered out of the compressor shaft (see photo above).
  • The pulley turns without transmitting power, because the teeth of the pulley are worn.

Repair

Replace the compressor.

Models affected

137 –
1F7 – EOS
1K1 – Golf V
1K2 – Jetta III
357 – Passat CC
3C – Passat / Passat Wagon
5K1 – Golf VI
5M1 – Golf V Plus
5N1 – Tiguan

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

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.

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

volkswagen_golf_rear_seat_rattle_fix_tape_before_001 volkswagen_golf_rear_seat_rattle_fix_tape_before_002

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

volkswagen_golf_rear_seat_rattle_fix_tape_after_001 volkswagen_golf_rear_seat_rattle_fix_tape_after_002

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

volkswagen_golf_rear_seat_rattle_fix_tape_old_001 volkswagen_golf_rear_seat_rattle_fix_tape_old_002

(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)

volkswagen_golf_rear_seat_rattle_fix_lock_mechanism_001

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

Sanden PXE16 Air Conditioner Compressor Specifications (1K0820803)

sanden_pxe16_air_conditioner_compressor_volkswagen_golf_1k0820803_001Sanden’s PX series next generation swash plate compressors are variable controlled for maximum environmental benefit, these compressors replace the Zelex and Valeo compressors that are prone to early failures – Volkswagen Golf, GTI, Passat, Jetta and Eos Air Conditioner Compressor Failure.

The PXE16 has a minimum displacement of 4.9cc, a maximum displacement of 163cc,  maximum speed of 8500RPM and 7 pistons. The displacement control is external and varies the compressor displacement without the use of an electromagnetic clutch. The unit runs all the time and varies output from 2% through to 100% as required.

Refrigerant used is R-134A and the oil used is SP-10.

View a video of the operation of the PXE compressor here (Internet Explorer required)