Volkswagen Cars 2000-05

Fuses, Fusible Links & Circuit Breakers

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The fuse link is a short length of wire, integral with the engine compartment wiring harness and should not be confused with standard wire. The fusible link wire gauge is smaller than the circuit which it protects. Under no circumstances should a fuse link replacement repair be made using a length of standard wire cut from bulk stock or from another wiring harness.

Fusible link wire is covered with a special thick, non-flammable insulation. An overload condition causes the insulation to blister. If the overall condition continues, the wire will melt. To check a fusible link, look for blistering insulation. If the insulation is okay, pull gently on the wire. If the fusible link stretches, the wire has melted.

Fusible links are often identified by the color coding of the insulation. Refer to the accompanying illustration for wire link size and color.

Circuit Breakers



Resetting & Replacement

Circuit breakers are located inside the fuse panel. They are automatically reset when the problem corrects itself, is repaired, or the circuit cools down to allow operation again.

Fuses



Maxifuse

Maxi-fuses are located in the engine compartment relay box. If a maxi-fuse blows, an entire circuit or several circuits will not function properly.

  1. Remove the fuse and relay box cover.
  2.  
  3. Inspect the fusible links to determine which is faulty.
  4.  
  5. Unplug and discard the fusible link.
  6.  
  7. Inspect the box terminals and clean if corroded. If any terminals are damaged, replace the terminals.
  8.  
  9. Plug in a new fusible link of the same amperage rating.
  10.  


WARNING
Never exceed the amperage rating of a blown maxi-fuse. If the replacement fuse also blows, check for a problem in the circuit(s).

  1. Check for proper operation of the affected circuit(s).
  2.  

Replacement


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Fig. Typical VW fuse box

Fuses are located either in the engine compartment or passenger compartment fuse and relay panels. If a fuse blows, a single component or single circuit will not function properly.

  1. Remove the fuse or relay box cover.
  2.  
  3. Inspect the fuses to determine which is faulty.
  4.  
  5. Unplug and discard the fuse.
  6.  
  7. Inspect the box terminals and clean if corroded. If any terminals are damaged, replace the terminals.
  8.  
  9. Plug in a new fuse of the same amperage rating.
  10.  


WARNING
Never exceed the amperage rating of a blown fuse. If the replacement fuse also blows, check for a problem in the circuit.

  1. Check for proper operation of the affected component or circuit.
  2.  

Use the provided plastic fuse puller located in the fuse panel to remove fuses. The lid of the fuse panel has a diagram of the fuse locations and amperage ratings for each circuit. The fuse is removed by simply pulling upward on the fuse with the removal tool.

The fuses are easily checked by visual inspection. With the ignition switch OFF , pull the fuse out of the holder. Check the fuse filament. It should be continuous and not broken. If the filament is broken, replace the fuse with one of the same amperage rating.



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Fig. Use a plastic prytool or if necessary a sturdy key can be inserted into the small slot in the cover. Carefully pry to cover off to remove-1.8L Passat shown



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Fig. The cover is held in place by 3 retainers-1.8L Passat shown



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Fig. Installed on the cover is a fuse chart and a removal tool-1.8L Passat shown



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Fig. The fuses have their amperage rating printed on them. They are color coded as well-1.8L Passat model shown

 
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