Intermittent Charge Warning Light ON, Low Voltage Indication on Gauge – 2008-2009 Volkswagen Touareg

Model(s)	Year	Eng. Code	Trans. Code	VIN Range From	VIN Range To
Touareg	2008-2009	3.6L (BHK)	All	7L_8D000001	7L_9D034155

 

Condition

27 10 02 July 14, 2010 2020793 Supersedes T. B. Group 27 number 09-04 Dated Nov. 11, 2009 to update warranty table labor operation time units.

Generator, Intermittent Charge Warning Light ON, Low Voltage Indication on Gauge

• Charge warning light ON.
• Voltage display of the voltmeter drops to 0 volts.
• Error messages in dash insert “consumer cut-off active”.

After switching the ignition OFF and ON the complaint is gone.

 

Technical Background

Incorrect voltage regulator installed in Valeo generators. Valeo generator Part No. 021-903-016 between production dates 51/07- 01/09.

 

Production Solution

Revised regulator Part No. 059 903 803G starting with VIN 7L_9D034156.

 

Service

Procedure

• Remove generator from vehicle, see Repair Manual group 27 in ElsaWeb.
• Gently pry off the voltage regulator cover, see illustration 1.

Illustration 1

 

• Carefully remove cap (A) for the voltage regulator, see illustration 2.

Illustration 2

 

• Remove voltage regulator retaining bolts (2) and pin (3).
• Remove voltage regulator.

Illustration 3

 

Tip:

DO NOT apply grease to commutater, see illustration 4.

• Position new voltage regulator and reposition bolts and pin.

 

Tip:

The Carbon brushes must not protrude from the opening of the protective cap. DO NOT depress regulator protective cap before tightening the regulator bolts.

Illustration 4

 

• Tighten voltage regulator bolts and pin to 2.6-4.8Nm (23-42 in. lbs.).
• To release the carbon brushes, press down cap (A), until it is flush with the voltage regulator housing.
• Install regulator cover previously removed in illustration 1.
• Install the generator, see Repair Manual group 27 in ElsaWeb.

Illustration 5

 

Warranty

To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and Procedures Manual 1)
Model(s)	Year(s)		Eng. Code(s)		Trans. Code(s)		VIN Range From		VIN Range To
Touareg	2008-2009		3.6L (BHK)		All		7L_8D000001		7L_9D034155
Claim Type:					Use applicable Claim Type 1)
SAGA Coding
Service Number:		Damage Code		HST		Damage Location (Depends on Service No.)		Parts Manufacturer (removed part)
2750		0040		—		Use applicable when indicated in ElsaWeb (L/R)		V L 2 2)
Labor Operation 3) :   Replace Regulator						27501950 = 20 TU
Labor Operation 3) :   Remove and install generator 3.6L FSI						27221919 = 130 TU
Diagnostic Time 4)
GFF Time expenditure			01500000 = 00 TU max.				NO
Road Test			01210002 & 01210004				NO
Technical Diagnosis			0132xxxx = 00 TU max.				NO
Claim Comment: Input “As per Technical Bulletin 2020793” in comment section of Warranty Claim.
1)  Vehicle may be outside any Warranty in which case this Technical Bulletin is informational only 2)  Code per warranty vendor code policy. 3) Labor Time Units (TUs) are subject to change with Elsa updates. 4)  Documentation required per Warranty Policy & Procedures Manual.

 

Required Parts and Tools

Part Description	Part No:
Voltage Regulator	059903803G

 

No Special Tools required.

 

Additional Information

All part and service references provided in this Technical Bulletin are subject to change and/or removal.

Always check with your Parts Dept. and Repair Manuals for the latest information.