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Volkswagen California 2010 Service Training

Summary of California 2010

  • Page 1

    Service training self-study programme 453 for the t5 2010 commercial vehicles.

  • Page 2

    2 s453_002 the self-study programme shows the design and function of new developments! The content is not updated. For current inspection and setting instructions, and workshop manuals, please refer to the service literature that is provided. Important note today, as in the past, the volkswagen comm...

  • Page 3

    3 introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 the model family of the t5 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 4

    4 the model family of the t5 2010 the 2010 model year will see the launch of an extensive remodeling of what is to become the fifth model generation of the transporter. Yet again, this vehicle will underline the pioneering role played by volkswagen commercial vehicles in the segment of people carrie...

  • Page 5

    5 s453_122 about the model range: ● predominantly for transporting people - window van, caravelle, multivan, california. ● in the other versions, the t5 2010 is chiefly used for transporting loads. ● within the model range, there are versions with both a short and a long wheelbase and three differen...

  • Page 6

    6 technical data platform van introduction s453_004 s453_104 s453_006 s453_005 platform van double cab platform van single cab the pictures only show selected variants and their dimensions/dimension ranges (e.G. With short and long wheelbase, etc.) - the chassis is not shown here. Please refer to th...

  • Page 7

    7 s453_029 s453_117 s453_030 s453_031 s453_145 panel van, window van, caravelle, multivan, california panel van multivan with the launch of the t5 2010, the multivan will also be available with a long wheelbase. The pictures only show selected variants and their dimensions/dimension ranges (e.G. Sho...

  • Page 8

    8 s453_124 s453_131 innovations on the front end in detail: – an engine cover with new lines and more angular beading – the engine cover extends further upwards and covers the wiper arms in the windscreen area. – in the lower area, the engine cover extends further into the radiator grille area. – th...

  • Page 9

    9 s453_054 structure of the front end - exploded view the double fan concept in the previous model will be discontinued - the t5 2010 now has a single fan exclusively. The cooling power is adapted to the equipment level by means of three different fan powers (450 w, 600 w, 850 w). Assembly mount ven...

  • Page 10

    10 s453_055 body assembly mount in contrast to the assembly mount in the previous model, the one in the t5 2010 is no longer made from steel but from a composite material comprising plastic with a steel insert. The main advantage is the increased weight saving. In order to guarantee the necessary st...

  • Page 11

    11 s453_108 the tailgate emergency unlocking function all model variants of the t5 2010 with tailgate are equipped with a tailgate emergency unlocking function. In case of an emergency when the tailgate can no longer be opened, e.G. Because: ● the tailgate or the opening mechanism has been damaged d...

  • Page 12

    12 s453_045 occupant protection as a feature of the volkswagen safety strategy, the occupant protection system in the t5 2010 has been improved in the form of a seat belt fastening warning and a modified airbag concept for driver and front passenger protection. Front airbag front passenger head airb...

  • Page 13

    13 s453_007 s453_123 s453_121 belt fastening warning one feature in the safety concept is the seat belt fastening warning for the driver's seat which is installed as standard. An acoustic signal sounds if the driver's seat belt is not fastened. In addition, a red warning lamp lights up in the instru...

  • Page 14

    14 the engine range includes one petrol and four tdi engines. The power plants are installed transversely. Engine as far as the gearboxes are concerned, there are 2 manual gearboxes and one automatic. The engine/gearbox combinations engine 5-speed manual gearbox 02z 6-speed manual gearbox 0a5 dsg au...

  • Page 15

    15 s453_018 s453_017 2.0 l/85 kw petrol engine the engine has been adapted for use in the t5 2010 with the modified installation position. Technical features – spray nozzles for piston cooling – oil pump driven by chain from the crankshaft – electrically heated crankcase ventilation – secondary air ...

  • Page 16

    16 s453_013 s453_011 2.0 l/62 kw tdi engine the diesel engine is a further development (2nd generation) based on the 2.0 l tdi engine in the tiguan or passat, which has been adapted for the installation conditions and the specific commercial vehicle requirements of the t5 2010. Technical features – ...

  • Page 17

    17 s453_012 s453_013 2.0 l/75 kw tdi engine the design of the 75 kw engine is based on the same engine as the 62 kw engine. The difference is only the modification to the control unit software used for the injection system. Technical features – common rail injection system – diesel particulate filte...

  • Page 18

    18 s453_013 s453_014 2.0 l/103 kw tdi engine the design of the 2.0 l/103 kw engine is also based on the same engine as the 62 kw engine. The difference is only the modification to the control unit software used for the injection system. Technical features – common rail injection system – diesel part...

  • Page 19

    19 s453_015 s453_016 2.0 l/132 kw tdi engine with bi-turbo unit the design of the 2.0 l/132 kw engine is based on the 2.0 l/103 kw engine, but it is equipped with a bi-turbo unit to provide a power boost. The control unit software has been adapted accordingly. Technical features (in addition to the ...

  • Page 20

    20 s453_026 s453_025 power transmission the gearboxes two manual gearboxes, the 02z and the 0a5 gearbox, and the dsg automatic gearbox 0bt are used in the t5 2010. They have been designed for transverse installation in the vehicle. 5-speed manual gearbox 02z the 5-speed gearbox is already familiar f...

  • Page 21

    21 the 7-speed dual clutch gearbox (dsg) 0bt is being used in the t5 2010 for the first time in the volkswagen group. From march 2010, it will be possible to combine the dsg with four-wheel drive in the t5 2010. It can also be used in heavy vehicles with a gross vehicle weight rating of up to 3.2 t....

  • Page 22

    22 power transmission rear axle box haldex coupling rear axle box the design of the rear axle box has been adapted for installation of the haldex 4th generation coupling and for the higher torque requirements in the t5 2010. As an option, the t5 2010 is available with a mechanical differential lock ...

  • Page 23

    23 s453_043 dual clutch gearbox 0bt bevel drive propshaft bevel drive the bevel drive has been adapted for the higher torque requirements in the t5 2010. Two different bevel drives are used, one of which is adapted for mounting on the manual gearbox and the other for the dual clutch gearbox..

  • Page 24

    24 s453_027 power transmission bevel box the housing structure, the bearings and the gears of the bevel box have been adapted for the higher torque requirements in the t5 2010. At the same time, it has been possible to reduce the weight of the bevel box by 6.25 kg compared to the previous type. Stru...

  • Page 25

    25 s453_132 rear final drive the design of the rear final drive has been adapted for installation of the haldex 4th generation coupling and for the higher torque requirements in the t5 2010, as far as the housing and the bearings are concerned. The reservoir tank for the haldex oil is an integral co...

  • Page 26

    26 power transmission operating lever for dog clutch drive to left wheel differential crown wheel with hypoid gearing ventilation rear axle box drive to right wheel cutaway view – rear axle box the rear final drive of the four-wheel drive t5 2010 consists of the haldex 4th generation coupling, the f...

  • Page 27

    27 s453_130 four-wheel drive control unit j492 multi-disc pack of the haldex coupling oil space haldex oil oil space final drive oil pump for haldex coupling v181 double oil seal pinion drive from propshaft double oil seal torsional vibration damper breather hole.

  • Page 28

    28 running gear overview of the running gear the basic structure of the running gear in the t5 2010 corresponds to that in the previous model. Some important components of the running gear have undergone further development. This means it satisfies the demands of driving even more effectively. ● rev...

  • Page 29

    29 s453_076 the picture corresponds to front-wheel drive. ● the rear axle design is adopted from the transporter 2004 ● new 17-inch dual piston brake on the front axle ● four-wheel drive now also with the new 7-speed dual clutch gearbox 0bt.

  • Page 30

    30 s453_034 s453_085 running gear esp (electronic stability programme) also combines the familiar functions: ● abs (anti-lock brake system) ● eds (electronic differential lock) ● tcs (traction control system) ● msr (engine drag torque control) ● hill hold assist the brake system esp system from mode...

  • Page 31

    31 the system has the following new functions in addition to those already named: function functional description arp (active rollover protection) arp minimises the risk of rolling over when cornering. If the transverse acceleration threshold value set for the individual vehicle is exceeded during c...

  • Page 32

    32 s453_082 s453_084 s453_083 running gear front brake on its front axle, the t5 2010 has a 16-inch brake system. The ventilated brake discs have the dimension Ø 308 x 29.5 mm. Rear brake the rear axle of the t5 2010 is fitted with 16-inch brakes. The ventilated brake discs have the dimension Ø 294 ...

  • Page 33

    33 s453_142 s453_143 brake light switch on main brake cylinder the mechanical switches on the pedal mechanism have been discontinued in all t5 2010 vehicles, and replaced by a brake light switch on the tandem main brake cylinder of the brake booster. This brake light switch is one component that com...

  • Page 34

    34 s453_081 s453_072 running gear the steering all t5 2010 vehicles are equipped with hydraulic power steering. Servotronic is available as standard for all multivan highline vehicles and is an option for all other t5 2010 models. It is a feature of servotronic that the steering support is reduced a...

  • Page 35

    35 s453_077 s453_114 adjustable steering booster pump the adjustable steering booster pump is mounted on the engine below the alternator, and is driven by the belt drive of the engine. It is used in all t5 2010 vehicles with a diesel engine. Structure and function ● the adjustable steering booster p...

  • Page 36

    36 s453_078 s453_080 running gear function at idling speed … the cam ring of the pump is pressed against the outer ring by spring force and the internal pressure conditions. This produces the greatest possible delivery volumes on the suction and pressure sides. The delivery volume increases as the r...

  • Page 37

    37 s453_079 as the rotation speed increases further … the delivery volume and pressure increase if the rotation speed continues to rise. The control piston is pushed further to the left against the spring force, and therefore the duct to the left chamber is connected to the suction line. The opposit...

  • Page 38

    38 s453_128 s453_129 s453_148 s453_149 heating and air conditioning climatic the climatic replaces the manual air conditioning system familiar from the predecessor. The desired temperature is set on the electronic temperature dial, and this value is reached by adjustment of the temperature flap depe...

  • Page 39

    39 s453_126 s453_125 the auxiliary heaters the t5 2010 can be equipped with the following auxiliary heaters: auxiliary heating ● airtronic d3/b3 plus auxiliary air heater (manufacturer: eberspächer) ● thermo top c auxiliary water heater (manufacturer: webasto) supplementary heater ● thermo top z aux...

  • Page 40

    40 the installation locations of the control units electrics control unit for left door engine control unit mdi control unit uhv control unit airbag control unit amplifier and tv tuner control unit for right door remote control receiver for auxiliary heating control unit for parking aid onboard supp...

  • Page 41

    41 453_089 control unit for lane change assist left control unit for lane change assist right control unit for reversing camera control unit for right sliding door left sliding door control unit control unit for voice amplification and cd changer control unit for trailer detection.

  • Page 42

    42 j519 j533 a j285 b c d j503 j255 r78 t16 r12 j772 j656 j345 j162 j412 j558 j731 r215 j362 j702 electrics the networking concept what the abbreviations mean e265 rear climate control unit e313 selector lever g24 tachograph g85 steering angle sender g303 interior monitor send and receive module 1 g...

  • Page 43

    43 s453_024 j788 g85 j743 j623 j234 e313 j446 j104 g419 j492 g24 j769 (master) j770 (slave) h12 g303 g384 j386 j387 j527 g305 g397 e265 j364 can data bus driveline can data bus comfort/infotainment can data bus sensor lin data bus can data bus line lin data bus line data line control line k-line a c...

  • Page 44

    44 s453_057 electrics the onboard supply control unit j519 the new onboard supply control unit j519 in the t5 2010 has had various functions added to it. In contrast to the onboard supply control unit in the previous model, it now also handles the functions of the convenience system central control ...

  • Page 45

    45 s453_069 control unit version range of functions of onboard supply control unit medium ++ - load management - control of electric fuel pump - terminal control/terminal registration - front and rear wiper control - horn control - battery isolation relay control - heated rear window control - heate...

  • Page 46

    46 s453_023 s453_022 electrics the lights headlights the external design and also the interior structure of the chambers of the headlight unit have been adapted to volkswagen's new style. As in the previous model, it has a clear glass structure and is installed in the two variants with h4 and h7 hea...

  • Page 47

    47 s453_135 s453_136 tail lights the t5 2010 has two different tail lights. In conjunction with the h7 headlight module, a new tail light is used which differs from the tail light in the previous model by its more striking design, its internal structure and the resulting distribution of the illumina...

  • Page 48

    48 ! Emergency brake display all model variants of the t5 2010 now feature the new "emergency brake display" function. The abs control unit j104 detects an emergency braking situation based on the stored threshold values for deceleration and/or the abs intervention time. It sets an emergency braking...

  • Page 49

    49 s453_099 fog light - static turning light if the t5 2010 is equipped with fog lights then these are also used for the function of the static turning light. The static turning light is switched on by the onboard supply control unit j519 in accordance with the vehicle speed, the steering wheel angl...

  • Page 50

    50 s453_102 s453_101 s453_071 s453_110 electrics the lane change assist the t5 2010 (closed bodies, short wheelbase and tailgate) is now available with lane change assist (side assist) as an option. The lane change assist warns the driver about vehicles that are located to the side in the "blind spo...

  • Page 51

    51 s453_103 the reversing camera system operates with a wide- angle camera in conjunction with a control unit. The camera is fitted in the number plate light. In the dark, the illumination in the rear area of the vehicle provided by the reversing light is sufficient to allow perfect function. The fi...

  • Page 52

    52 s453_008 s453_009 electrics the dash panel the dash panel has been revised for the t5 2010. Overview of new features: revised lines, surfaces, newly designed dash panel inserts, completely new radio/navigation range and updated controls for heating/ventilation and air conditioning systems. The jo...

  • Page 53

    53 s453_134 s453_133 s453_086 s453_140 s453_144 the t5 2010 is optionally equipped with the media device interface box (mdi box). It makes it possible to connect portable audio and memory devices and to play back their audio files via the radio or navigation system. The media device interface box is...

  • Page 54

    54 technical data rcd 210 monochrome display 122 x 36 pixels colour display, touchscreen fm, tp and rds reception (single tuner) ● fm twin tuner for fm, tp and rds reception with phase diversity am reception ● integrated dab tuner (digital radio) radio data system (rds) ● tmc function and tmc backgr...

  • Page 55

    55 rcd 310 rns 310 rns 510 302 x 45 pixels 5.5-inch, 400 x 240 pixels 6.5-inch, 800 x 480 pixels ● ● ● ● ● ● depending on equipment ● ● ● ● ● ● ● ● ● (dvd player) ● ● cd, mp3 and wma audio data cd, mp3 and wma audio data, navigation data cd, mp3 and wma audio and dvd video data, navigation data ● ● ...

  • Page 56

    56 s453_038 s453_037 gps gsm s453_115 radio, phone and navigation the aerial concept the t5 2010 has a complete aerial system for radio, tv, phone and gps integrated in the exterior mirrors. The mirrors are configured as module exterior mirrors or exterior mirrors on extension bars depending on the ...

  • Page 57

    57 s453_039 s453_040 s453_116 gps am/fm gsm exterior mirror on extension bars for open bodies left exterior mirror the am/fm aerial is located on an aerial foil with associated signal pathways. The gsm aerial is located on a separate aerial foil on the inside of the mirror housing. Right exterior mi...

  • Page 58

    58 s453_063 am/fm am/fm/gsm am/fm/tv/gsm s453_065 s453_066 s453_062 s453_044 without fm2 fm2/dab/gps fm2/tv/gps aerial assignment - module exterior mirror each of the aerial combinations shown in the picture is possible for the module exterior mirrors. Exterior mirror left exterior mirror right radi...

  • Page 59

    59 am/fm am/fm/gsm s453_138 without fm2 fm2/dab/gps s453_067 s453_064 s453_139 s453_068 aerial assignment - exterior mirror on extension bars each of the aerial combinations shown in the picture are possible for the exterior mirrors on extension bars. Mirror aerials am, fm, dab aerial with impedance...

  • Page 60

    60 s453_050 am/fm b b b s453_141 radio, phone and navigation aerial - onboard power supply connection the am, fm, tv and dab aerials need antenna mounts that are located inside the doors. To ensure a perfect earth connection to the doors, the doors have an earth connection to the body earth via a se...

  • Page 61

    61 456_047 d d gsm b am/fm c a gps dab i fm b b i a a rcd310 d uhv d s453_046 b b d uhv d d d gsm b am/fm rcd210 aerials - radio rcd 310 and uhv/dab left exterior mirror – am/fm aerial – gsm aerial (with uhv) right exterior mirror (with dab) – fm2/dab aerial – gps aerial (not used) right exterior mi...

  • Page 62

    62 456_048 456_049 d d gsm b am/fm c a gps dab i fm b b i c d d gsm b am/fm f c tv gps i fm b b i c c e rns 310 rns 510 f d uhv d d uhv d c f tv e radio, phone and navigation left exterior mirror – am/fm aerial – gsm aerial (with uhv) left exterior mirror – am/fm/tv aerial – gsm aerial right exterio...

  • Page 63

    63 s453_053 j503 r38 j412 r38 j285 j519 e440 e441 j503 r38 audio j412 s453_051 the telephone preparation uhv the telephone preparations used in the t5 2010 are uhv with audio streaming and uhv premium. These must be paired with bluetooth tm -capable mobile phones. Uhv (bluetooth tm low) with audio s...

  • Page 64

    © volkswagen ag, wolfsburg all rights reserved. Subject to technical modifications. 000.2812.33.20 technical status 11.2009 volkswagen ag after sales qualifizierung service training vsq-1 brieffach 1995 d-38436 wolfsburg ❀ paper made from cellulose bleached without the use of chlorine. 453.