VW T6.1 2019 - bozzio.ch · VW T6.1 2019, Vehicle Specific Installation Manual Bozzio AG * joysteer® page 3 of 48 1 General This document describes the installation of the joysteer®

a product of the company Bozzio AG

VW T6.1 2019

Vehicle Specific Installation Manual

EN_VW_T6.1_Specific_Installation_Manual_2_V01-200430.docx

Aarbergstrasse 5 2560 Nidau Switzerland

VW T6.1 2019, Vehicle Specific Installation Manual

Bozzio AG * joysteer® page 2 of 48

Content

1 GENERAL .................................................................................................................. 3

2 DISCLAIMER ............................................................................................................. 4

3 INSTALLATION OF VEHICLE SPECIFIC PARTS ..................................................... 5

3.1 Installation of electronics ......................................................................................... 6

3.1.1 Part list ........................................................................................................................ 7

3.1.2 Installation steps ......................................................................................................... 9

3.2 Installation steering actuator module (SAM) ......................................................... 16

3.2.1 Part list ...................................................................................................................... 17

3.2.2 Installation steps ....................................................................................................... 19

3.3 Installation brake actuator (BAM) .......................................................................... 32

3.3.1 Part list ...................................................................................................................... 33

3.3.2 Installation steps ....................................................................................................... 35

3.4 Installation brake pressure sensors ...................................................................... 44

3.5 Park Position (CAN Adapter or P-switch) .............................................................. 46

3.6 Installation backup-battery ..................................................................................... 48



1 General

This document describes the installation of the joysteer® system and to take place by trained personnel exclusively, whereby all points need to be carried out as described.

This document is in addition to the "Universal System Manual".

The electrical connections can be found in the electrical cabling diagram.

This document applies to the joysteer® system generation 2.0.

The main change from generation 1.0 to generation 2.0 is as following:

Display module Alarm module

joysteer® generation 2.0 joysteer® generation 1.0



2 Disclaimer

Bozzio AG refuses their product liability if one or more of the following facts are given:

• Driving the system by users who do not possess an appropriate driving licence Exception: driving accompanied by an authorized driving instructor

• Driving with accompanying driving instructor without installation of an instructor Switch

• Installation/ maintenance/ repairs by companies not trained by Bozzio AG

• Installation/ maintenance/ repairs by personnel not trained by Bozzio AG

• Installation/ maintenance/ repairs not according to the manuals

• Installation/ maintenance/ repairs of components/ modules, which are not mentioned in the part list

• Installation/ maintenance/ repairs of any MMI (Man Machine Interface), which has not been released by Bozzio AG in written form

• Usage of parameter-sets which do not correspond to the “rules” of the Servicemanager

• Any modifications to the cable harness

Important:

• By opening the modules any warranty of the manufacturer is omitted

(Exception: EnergyAlarm module)



3 Installation of vehicle specific parts

Choose a sensible order to install: The correct order of installing each component of the joysteer® system is depending on which components have to be installed.

Example: If you first install the steering actuator, it is harder to reach the brake pedal and the gear shifter.

Preparation:

• Any floor/B-pillar modification (welding) must be done before installing any electronic equipment.

• Make connections to the steering column module for secondary controls before mounting any joysteer modules.

• Modify or move the ignition switch if necessary.

• Install the mechanical parts of the gear shifter including P-switch before mounting any joysteer modules.

• Check if a newer SW Version is released. The downloads are available in the login domain of www.joysteer.ch.

joysteer modules:

The proposed order of installation for this car type is the following:

1. Mount the Electronics (Converter and EAM).

2. Connect the wiring harness to the CM/EAM and put all the wiring in the desired position.

3. SmartGas 2

4. Brake pressure sensors. To be done while the original pedal is still in place so it’s possible to purge the system immediately after mounting the sensors.

5. P-Switch.

6. Brake actuator BAM

7. Steering actuator SAM

8. Backup battery and Pulse Test Box

http://www.joysteer.ch/



3.1 Installation of electronics

The modules and if available the module rack (optional item) have to be grounded well. In case this is done with a cable, the cables cross section must be at least 2.5mm2.

If the module rack is required, all modules are to be connected to it.

The installation order of modules from top to bottom is always:

EAM = EnergyAlarm module

L1 = Steering converter module 1

L2 = Steering converter module 2

B1 = Braking converter module 1

B2 = Braking converter module 2

EAM

L1

L2

B1

B2



3.1.1 Part list

(Images not to scale)

Image Description Pcs.

Threaded pin 1

Module rack 1

Cover module rack 1

Lower plate support 1

Blind rivet nut 2

Hexagon bolt M6x25 2

Washer M8 2

Hexagon socket countersunk M4x10 10


Washer M6 4

Locknut M6 2




Plastic ring M6 4

Plastic cap M6 4

Washer M6 4

Hexagonal nut connector M8 1

Nut M8 1

Flange nut M8 2



3.1.2 Installation steps

1. Remove the negative pole from the battery

2. Remove the glove box and the dashboard covers on the right side of the vehicle and pull the vehicle floor mat to the back so the vehicle bottom plate is visible.

3. Specify the hole pattern for the blind rivet nuts by using the lower plate. Refer to picture for dimensions.

4. Drill holes into the lower plate support and mount the blind rivet nuts.

5. Mount lower plate support

Use:

• 2 bolts M6x25

• 2 washers M6

• 2 washers M6x 2mm, to be placed between the lower plate and the floor.

Note: Mount the lower plate support according to picture above

A



6. Remove the shown bolt from the engine compartment and mount one M8x25 and one washer M8 in the engine compartment. Mount one Hexagonal nut connector M8 in the car’s interior side.



7. Remove a piece of foam under the floor mat, cut out the contour of the lower plate support and remove a small piece of floor mat where the hexagonal nut connector M8 is mounted. All as shown in the pictures below.

8. Mount the Threaded pin, with on one side a flanged nut and on one side a contra nut M8, to the Hexagonal nut connector. Make sure a contra nut is secured.



9. Mount the modules L1, L2, B1, B2 und EAM to the bracket

Use:

• 10 hexagon socket screws M4x10

• 4 hexagon bolts M4x10

Note: Use one of these bolts to secure a ground cable. Make sure the module bracket and the modules are grounded well.

10. Mount the module rack to the lower plate support

Use:

• 2 nuts M6x16

• 4 washers M6

• 2 locknuts M6

Note: The hinge needs to stay loose – only tighten the screws so this is the case



11. Mount the module rack to the threaded pin

Use:

• 1 flanged nut M8

12. If required, the position of the module rack can be adjusted with the threaded pin

13. Cut of the heater outlet and attach included tube using the clamps, as shown below.

Use

• 1 Tube

• 2 Clamps



14. Mount back the dashboard covers and the glove box.

15. Mount the Tube to the cover using a clamp and mount the cover to the module rack.

Use

• 4 plastic rings

• 4 nuts M6

• 4 plastic caps



To finish

1. Reconnect the negative pole to the battery 2. Test full functionality of the system



3.2 Installation steering actuator module (SAM)

Ensure the following:

• The steering actuator is placed between the steering wheel and the steering column. There is no need to detach the steering column.

• In case of an adjustable steering column the steering column needs to be fixed permanently.

• the steering wheel is always in the straight-ahead position during the installation

• the airbag-ring is in the middle position when installing

• the locking pins of the airbag-ring must sit correctly in the steering actuator

• if needed these can also be lengthened by using a synthetic tube

• the spacers are placed in-between the steering column and the assembly brackets

Beware: when adjusting/ re-assembling the steering wheel lock / ignition as it needs to be reassembled in exactly the same way.

(picture is a schematic view / indication)

SAM

Pins for the airbag-ring



3.2.1 Part list



Steering wheel adapter 1

Steering wheel bolt + Washer 2

Actuator bracket 1

Assembly bracket 2

Top assembly bracket Left + Right 2

90 degree bracket 2




Mounting support bracket 1


Washer M8xD20X3mm 2

Locknut M8 9

Washer M8 thick 12

Hexagon bolt M8x30 kw.8.8 6

Hexagon socket countersunk M6x10 4

Cylinder head screw M5x12 7




Washer M8 6

Note: This symbol indicates the usage of Loctite.

Always use Loctite 243 unless otherwise mentioned. The required torque is mentioned below the symbol.

..Nm




Steering wheel adapter

Steering actuator

Assembly bracket

Assembly bracket

Top Assembly bracket L+R




2. Remove the steering wheel airbag

3. Remove the steering wheel

4. Remove the steering column covers

5. Remove the tacho cover by pulling if forward

6. Remove he tacho by removing the 2 lower torx bolts and pulling it forward.



7. Cut out the plastic cover behind the tacho as shown. So, the 2 torx bolts behind can be

reached easily.

8. Remove ignition and steering wheel lock (remove shear bolts)

9. Remove or cut off the steering wheel lock (in the red circle) from the ignition lock. Do not

disconnect the steering wheel lock electrically. Or move the ignition lock to a different

place in the vehicle. In that case it does not have to be adapted.



Adaptation of ignition lock, Removal of steering wheel lock

This is only necessary if the ignition lock stays in place and the locking pin is not cut off.

10. Insert the key in the ignition lock and put it on ACC (the little hole stands in line with the

mark on the plastic part. Picture below D.

11. Insert a thin pin into the hole and remove the cylindrical part from the ignition lock as

indicated with D*.

12. Remove the white plastic circlip from the ignition lock

13. Disassemble the entire ignition lock and remove the steering wheel lock (E).

To remove the inner parts, it’s needed to sand of the round bulge, indicated in the blue

circle on the above picture (previous page).

D*

D



E



14. Re-mount the ignition lock

Use:

• 2 cylinder head screw M8x16

• 2 washers M8

15. Screw the adapter to the steering actuator

Use


Use Loctite

16. Mount the actuator bracket to the steering actuator module

Use

4 hexagon socket countersunk screws M6x10

17. mount the two 90degree brackets to the actuator bracket

Use 2x Cylinder head M8x25 4x Washer M8 2x Locknut M8

7.6Nm

4.5Nm



18. Adapt the steering column cover according to the pictures shown below.



20mm

135mm

170mm

185mm



19. Remove the adjusting mechanism of the steering column completely

20. Remove the 2 springs shown below

21. Remove the cable tree guide as shown



22. Remount the modified dashboard cover

23. Mount the assembly brackets to the steering column

Use:

• 1 hexagon bolt M8x90

• 2 washers M8

• 1 locknut

24. Mount the 2 top assembly brackets and use the 4 original torx bolts to secure them.

Remove springs



25. Cut out the plastic part as shown so the bracket has space when the steering column is in the most upward position.



26. Place the steering actuator module onto the steering column and use the steering wheel bolt to position in the centre.

27. Mount the steering actuator module to the assembly brackets

Use:

• 2 bolts M8x30

• 4 washers thick M8

• 2 locknuts M8

28. Position steering wheel in its highest position.

29. Mount the 2 assembly brackets to the assembly bracket.

Ensure the steel strips are mounted correctly.

Use

• 4 hexagon bolts M8x30

• 8 washers M8 heavy

• 4 locknuts M8

30. Mount both assembly brackets to the other end of the steering column with the original screws.



31. Tighten the screws and nuts in the following order:

• Steering wheel bolt

• Screws of the motor unit bracket

• Screws of the assembly bracket

• M8x90 of the steering column adjusting mechanism

In case there is not enough free play in the slot holes; loosen everything adjust and tighten again.

Important:

Check if the installation is correct by driving the car conventionally after having installed the steering actuator. As the worm wheel and the motors are rotated passively, there is an increase of friction. Whilst the joysteer® system is turned off the friction of the steering actuator should not increase significantly. If this is the case, the steering actuator is misaligned, and the screws of the brackets need to be loosened slightly. By sequential tightening of the screws, the alignment of the steering column to the steering actuator is ensured and thus the friction can be minimized.

To finish

1. Reconnect the negative pole to the battery

2. Test full functionality of the system

3. Friction test by conventional driving



3.3 Installation brake actuator (BAM)

The brake actuator is attached to the brake pedal.

Always ensure the pin is not under tension and that the locking clip is attached properly.



3.3.1 Part list



Pedal bracket 1

Axis pedal bracket 1

Axis brake pedal 1

Mounting support bracket 1

Locking pin with circlip 1

Spiral Tube 1





Nut M6 1

Lock ring M8 1

Locknut M8 1


Self tapping screw 4,2x13 2

Hose Clamp 2




Locking pin with circlip

Axis brake pedal

Mounting support bracket

Axis pedalbracket

Pedal bracket

Brake actuator




2. Remove the lower cover of the dashboard and the cover above the pedals.

3. Mount the pedal bracket to the brake pedal and place it on the axis

Ensure, the pin is placed on the top and secure it

Use:


• 1 nut M6

Note: Do not yet tighten the screws.

4. Cut the dashboard as shown on the picture below

Note: Remove the purple OBD diagnose connector and mount it on an easy to reach location in the vehicle. Tighten it using a Tie-wrap.





5. Remove the 4 nuts of the original brake pedal bridge, so there is sufficient space to fix the axis (ref. step 8).

6. Mount the mounting support bracket.

7. Mount the axis in the pivot point of the brake pedal,

Use:

• 1 lock ring M8

• 1 locknut M8

8. Place the 4 original nuts to mount the brake pedal. Use the lower nuts to mount the assembly brackets.

113mm

110mm

90mm



9. Cut off the heater outlet as shown and mount the tube in between both parts. Use the 2

supplied hose clamp.

10. Cut the dashboard mid cover so the spiral tube will fit trough as shown on pictures below.





11. Mount the brake actuator to the brackets

Use:

6x cylinder head screws M5x6

12. Insert the locking pin. This connects the brake actuator to the brake pedal. Use the circlip to secure the locking pin.

Ensure the circlip is mounted the right way and it is well placed in the groove of the pin

13. Ensure the pedal bracket and the brake actuator are properly aligned



Tighten the cylinder head screws (step 3) and secure with a nut M6

14. Mount the heater outlet to the dashboard.

Use:

1x self-tapping screw 4.2 x 13

210mm

80mm

35mm



To finish

1. Reconnect the negative pole to the battery

2. Test full functionality of the system

3. Ensure the locking pin can be rotated by hand. This ensures that the brake actuator is not under mechanical tension or misaligned when in its idle position.

210mm

80mm

35mm



3.4 Installation brake pressure sensors

Remove the original brake hoses from the hydraulics to the ABS manifold block Mount the brake hoses and brake pressure sensors as shown below



1 4363314010

2 4363314020

3 4363314030

4 4363314040



3.5 Park Position (CAN Adapter or P-switch)

The Park Position is safety critical and is recognised by the joysteer® system.

There can be found 2 installation methods to detect the safe Park Position. Either with a CAN Adapter or with P-switches. The Installation of the CAN Adapter is universal and shown in the System manual. However, the installation of the P-switches is car specific as following:

1. Remove the upper gear shifter cover.

2. Remove the original torx bolt on the right side of the gear lever.

3. Mount P-switch bracket to the gear lever unit using 1x tapping screw 4.8x32.

4. Mount the 2 switches using 4 washers M3 and 4 screws M3x16.



Drawn: not in park, switch not operated



3.6 Installation backup-battery

The backup-battery is placed underneath the passenger seat.

Ensure the following:

1. The mass cable of the backup-battery should not be connected to the vehicles body. It needs to be connected to the EnergyAlarm module using a cable.

2. All consumers such as ramp door, lift etc. need to be connected to the vehicles primary battery.

3. For safety reasons the backup-battery must always be as specified in the Universal System Manual.

Next installation steps

4. Apply ring cable shoes (10mm2/M6) to the backup-battery

5. Place fuse near the backup-battery 125A (adapter included)

6. Apply vent hose on the backup-battery

Make sure that the gases are led out of the vehicle (If required; drill a hole and make a tulle)

7. Connect the EnergyAlarm module to the battery

8. Place ring cable shoes (10 mm2/M6) to the original battery

9. Place fuse 125A near the original battery (adapter included)

10. Apply ring cable shoes (10 mm2/M8) to the negative and positive pole of the battery

11. Mount them to the original battery clamps

VW T6.1 2019 - bozzio.ch · VW T6.1 2019, Vehicle Specific Installation Manual Bozzio AG * joysteer® page 3 of 48 1 General This document describes the installation of the joysteer®

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